Chapter 3 - Hydraulic

7/28/2019 Chapter 3 - Hydraulic

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Chapter 3

Research Design and Methodology

3.0 Research Methodology

This chapter presents the principles and methodologies involved by the proponents in

order to realize a research plan and creation of the proposed design improvement for the

hydraulic press for the Jatropha oil extraction. Furthermore, the step-by-step procedure used in

the design will be discussed.

3.1 Methods of Research

The proponent used experimental method in combination with data gathering technique.

Data gathering technique included library research, survey of people involved in the subject

matter and internet research. Data gathering was used to determine the proper design of the press

and to ensure the reliability of the prototype to test the efficiency and effectiveness of the

proposed hydraulic press. A set of experiments was performed in an accurate and precise way.

3.2 Development of the System

This part discussed the methodologies and principles used by the proponents in designing

the prototype, in accordance to the data gathered.


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Design Consideration

The procedure for the design of the hydraulic press started with assessing the existing

design used in DOST. Through observation of its operation, we realized some constraints in the

design as well as its processing time. We have also gained the fact that the proposed 6% oil

content by weight of the Jatropha seed was not fully recovered from the pressing process. Our

experience in DOST Jatropha facility gave us our first data on what to improve on the hydraulic

press. Presented below is the data we acquired from the three trials we observed when Engr.

Mallinllin showed us a demo using their hydraulic press.

Table 3.1 Data of DOST hydraulic press Jatropha oil extraction

TRIAL Mass of seed Operation Time Volume of oil

recovered

% oil content

recovered

1 200g 29mins 15mL 38.25%

2 200g 25mins 17mL 43.35%

3 200g 22mins 18mL 45.9%

To compute for % oil content per 250g of seed we used the following equations:


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Trial 1

Trial 2

Trial 3

The first trial showed us a result of 38.25% oil recovered from pressing the 250g Jatropha

seed. Also, 25 minutes was consumed during its operation. The second trial proved to be more

efficient than the first trial since it gave us a higher yield of 43.35% and the same weight but its

operation time took longer than the previous trial. The last trial showed us a remarkable

improvement in oil recovery since the percentage of oil recovered is 45.9% having the same

weight but in a lesser operating time of 22 minutes. Although there is an increasing percentage

of oil recovery it is still not enough to prove the theoretical oil content of the Jatropha seed.

These data just shows that the expected 6% oil content by weight recovered is not accomplished

in the demonstration. Thus we take note of the results and information we acquired, as a basis on

improving the design for oil extraction process using a manual hydraulic press.

The proceeding pictures shown are the actual design provided by the DOST for Jatropha

oil extraction.


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Figure 3.1: Photos taken in

DOST Jatropha Research facility

(top-left: Engr. Mallinllin

demonstrating a demo operation

of the Hydraulic press; top-right:

the pressing tool and the

pressing chamber: bottom-left:

Hydraulic set-up; bottom-right:

proponent holding the pressing

chamber after the pressing)

The hydraulic press that was used in DOST provided us oil yield but based on our

observation the procedure when the pressing was conducted was stressful. Certain problems

arises as we were conducting the demo such as difficulty in the return of the spring, difficulty in

adjusting the stroke and aligning the pressing tool, and a stressful work since sometimes it takes

three pressing procedure is needed in order to release seed oil. All of these observations came to

our mind that we need to design a better hydraulic press.


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3.3 Methods of Developing the System

This section provided the step-by-step procedure of the proponents in designing the

proposed hydraulic press. This section included explanation how a hydraulic press works, heat

band function, design parameters and material selection, the construction of the actual prototype,

and the final design specifications.

3.3.1 Principles Used in the Design

The basic operation used in the design doesnt go far from what we have witnessed from

the Hydraulic press in DOST. But in order to realize our objective, the design that the proponents

created, provided a much easier operation, more efficient in terms of time and oil yield, durable

and cheap to fabricate and maintain for a small scale operation.

3.3.2 Basic principle of the Hydraulic press used for Jatropha oil extraction

The basic principle that encompasses the Jatropha oil extraction using hydraulic press

includes simple understanding of physics. The seed was filled in a filter cloth or a sack and then

is put into a pressing chamber, made from a perforated cylinder, which was then pressed using

the hydraulic jack with the aid of a pressing tool. In order to prevent misalignment a guide post

was attached to the hydraulic jack plate. The compressive force induced by the hydraulic jack

created pressure on the seed which at a point of pressure the oil from the seed was released.

Extension springs was used to create a returning force to pull back the hydraulic jack piston


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when the pressure relief valve is released. The compressed cake, however, will be pulled out

manually by pushing the sack or filter cloth with a hammer tool.

3.3.3 Heat Band function

The heat band is a type of heating element that provides heat to another surface. Heat

band is mostly used in cylindrical shapes such as pipes, tubes and cylinder shaped-metals that

needed heat addition. According to the data gathered from P.Beerens, a cooker is a helpful

addition to increase oil yield. The heat band will be controlled using a thermo-controller in order

to obtain the right temperature needed.

3.3.4 Design Methodology

This section shows how the proponents design the proposed hydraulic press using

considerations on available raw materials and calculations to verify the acceptability of the

design parameters that we will use.

1. Consideration on amount of seed per batch.

The proponents started the design by considering the desired mass of jatropha

seeds to be pressed. We decided that 1/2 kg of seeds must be the mass per batch and

to increase the oil extraction we grounded the seed using a blender.


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The proponents computed the pressed volume that a mass of 1/2kg grounded

Jatropha seeds can have. Using the data in chapter 2, the solid density of jatropha

seeds is 1020 kg/m3. Using formula V =

we can get:

V =

= 4.902 x 10-4

m3

2. Design consideration for Hydraulic Jack

According to P.Beerens research on Jatropha

oil extraction, he stated that the design pressure

required for pressing jatropha seed to expel oil was

between 3MPa to 40Mpa. By computing the force

capacity, we computed how much pressure the

hydraulic jack can produce. Using the equation of

pressure P = we got the pressure that can becreated. For the calcuated area, we used the

formula provided by M.Modh from Ganpat

University, India, where in his paper he designed a small press chamber for an oil

expeller which is A = D h and for the force, we used

F = (Capacity x x 9.81 m/s2

)

F = (15 ton x

x 9.81 m/s2)F = 146 150 N

Fig. 3.2: Hydraulic press


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3. Design consideration for Pressing Chamber

After the hydraulic jack capacity was chosen, the proponents designed the

dimension for the chamber. To determine the height of the chamber, we measured the

actual height measured by putting the grounded seed at the tube. There are only three

size of pipe available during our canvassing these are 138mm, 248mm, and 158mm.

The proponents decided to choose the 158mm diameter mild steel pipe. After filling

up the pipe the actual height of kg grounded seed measured 145mm, so for the

height of the chamber we concluded to make it to 160mm for clearances and to

prevent spillage. From the computed pressed volume, we determined the height

produced during the pressing of the grounded seeds.

Since the cylinder has a 158mm diameter, using the equation h =

we gotthe pressed height established by 1/2 kg of seed.

D

H c

h

Fig. 3.3: Pressing Chamber


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h = = 25.09mm

In order to check for the validity of the material that will be used, we calculated

the pressure that can be created using the 15 ton hydraulic jack.

P =

= 11.82 N/mm2 or MPa

The calculated pressure for 15 tons was 11.82 MPa and the proponents decided to

use a mild steel pipe that is readily available for purchase. The mild steel pipe had an

ultimate strength 841 MPa and according to R.W.I Brachman and R.P Krushelnitzky,

the factor of safet that can be used on perforated pipes is 3.0. Perforation of the

chamber was required in order to provide holes where the seed can expel oil during

the pressing process even though from the experience we got in DOST most of the oil

was released below the chamber.

For the calculated allowable stress, we used the equation a = .

a =

= 280.33 MPa

For the calculation of the stress inside the chamber, we used the equation S s =

where the pressure inside the chamber was 11.82 MPa and the locally

available size of the inside diameter and the outside diameter of the pipe were 158mm

and 170mm respectively.

Ps = 11.82 MPa = 11.82 N/mm2


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Ss = = 86.79 N/mm2 or MPa

Since 86.79MPa < 280.33MPa the selected pipe dimension was acceptable.

4. Design consideration for Press Tool

The design of the press tool depended on the inner diameter of the press chamber

which was 158mm. We considered an allowance of 2mm on the creation of the piston

head to create a smooth stroke when pressing. The material that was used for the

piston head was a steel plate having 10mm thickness. The length of the press tool

shaft considered the stroke needed for the height of a 0.5kg grounded Jatropha seed.

L= 160mm25.32mm = 134.68mm

The press tool was decided to be adjustable so in order to do so, we decided to use

a two 32mm threaded stainless steel shaft together with a 76.2mm mild steel shaft

with threads reaching 50mm deep at both ends with countering direction. The upper

thread was clockwise oriented and the lower end was counter-clockwise oriented.

Using the computed length required for the press body, we decided to cut the

threaded rods at 70mm and the adjuster shaft at 120mm giving an initial length of

140mm and can be extended for another 100mm.


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`

For the computation of the acceptability of the material used, we used the

equation P =and compared it with its allowable stress using allowable =

The same formula from determining the stress of a material using surface area

which was shown in M.Modh formula of stress in mild steel is used to determine the

stress involved in these materials. Where: A =; D= diameter of material; L=length of material; Pss = pressure produced by the press tool shaft; Pms=pressure

Ls.s

Lo.s

Lm.s

Ds.s

Do.s

Dm.s

Fig. 3.4: Press Tool


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produced by the press tool mild steelshaft; Pcp=pressure induced to the circular plate

which is the press tool head and the press tool base; for the factor of safety it is based

on B.K Sarkars book, Strength of materials, Stress and Strains for Mild steels

which is between 2 and 6. In this context we will use 6 to maximize the safety of the

design since high pressure is involved in this process.

;

;

;

Factor of safety = 6

Pss =


= = 91.66 MPa

Pms =

= 20.91 N/mm

2or MPa

= = 140.17 MPa


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Pth =


=

= 41.67 MPa

For threaded stainless steel we had 20.91MPa < 91.66 MPa;

For mild steel, 20.91 MPa < 140.17 MPa;

And for press tool head and base, 30.03MPa < 41.67MPa.

Since the stainless steel threaded rod, mild steel adjuster and the press head

stresses were below their allowable stresses we conclude that the materials are

acceptable.

By joining all the length of the materials to be used, where the body of the press

tool shaft was 130mm, the press head of 60mm and 10mm for the press base, it would

sum up to:

Lpress tool = 130mm + 60mm + 10mm = 200mm

Therefore the total length of the actual press tool is 200mm.

5. Design consideration for Spring and Spring holder

To be able to have a fast return of jack piston when the pressure value is relieved,

a spring was appointed by the proponents to force return the jack piston into the battle


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frame. For determining if the locally available spring was acceptable, we used the

equation Fs = kx. If the returning force of the spring is greater than the force of the

jack then it is considered acceptable. Since the motion of the spring was longitudinal,

we used:

k =

where E = elastic modulus = 200 GPa = 200 000 N/mm2

A = circular area = (D2)

L = free length = 240mm

D = 5mm

s= Ds

Lf

Fig. 3.5: Tensile Spring


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k = = 16 362.46N/mm

Fs = Kx

According to spring data that we have gathered from the spring calculator

program of www.planetspring.com and the www.centuryspring.com spring data table the

maximum elongation of the spring to be used was 170mm.

x = elongation = 170mm

Fs = 16 362.46N/mm x 170mm = 2 781 618.2 NAnd FJ = = 147 150 N

Since Fs > FJ we therefore concluded that the spring was accepted

For the spring holder, a high threaded rod was welded, having a diameter of 12mm

and joined to a steel nut having a hole of 7 mm just right to fit the wire diameter of

the spring which was 5mm. Four holes at the jack plate and another four at the top

plate were used to fit in the spring holder. Another nut was torqued to the other end to

serve as its stopper and have the ability to adjust whenever the spring will be

changed. For computing of the spring holder strength, we used the formula of the

weld strength formula.


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Pw=0.5Ue

Where Pw= weld strength; Ue= minimum tensile strength of the electrode.

According to www.bssa.org.uk Ue of stainless steel electrode is 520MPa. Substituting

the variables to the equation:

Pw=0.5(520MPa)

Pw=260MPa

For determining the load capacity of the spring holder, we used the formula from

www.roymech.co.uk for weld strength.

Where

hw

bw

Fig. 3.6: Spring holder


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We used b= 12mm and h= 15mm

Substituting the variable to the equation we got

=46 800N

Since FJ = 147 150 N and there were four spring holders at each corner, the force was

distributed evenly at the spring holders.

For the computation of the force induced at each spring holder by the force of the 16-

ton jack, we used the formula:

Fig. 3.7: Spring Set-up

1

4

3

2


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Since we can say the design of spring holder was sufficient to hold the spring.

6. Design consideration for Press Frame

The press frame design was composed of four rigid pillars and three steel plates.

The pillars also acted as guide posts for the vertical movement of the jack plate. The

steel plate that was considered as the jack plate therefore the jack plate was placed in

the middle of the base and top plate.

For the four pillars, a stainless steel shafts that were locally available were used.

The available pillars size that were used were 50mm in diameter, the plates those

were 3pcs were 300mm x 300m x 10mm and one piece plate was 400mm x 400mm x

19mm. For the determination of the length of the pillars, the proponents considered

first the height of the pressing chamber, the hydraulic jack, pressing tool, the

hydraulic jack extender and thickness of the plates. For the calculation the length of

cut for the shafts, we added length of the said considerations.


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Total length = height of hydraulic jack spring + height of press chamber + max height

of extender + press tool height

Spring length with spring holder = 240mm

Press chamber = 160mm

Extender = 100mm

Press tool = 200mmm

Total length = 240 +160 + 100 + 200 = 700mm

We used 850 mm to accommodate the thread at both ends of the shaft. Each

thread of the shaft had a length of 70 mm and a pitch of 6 threads per inch. The major

400mm x 400mm x 19mm




700mm

Fig. 3.8: Press Frame Set-up


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diameter of the shaft thread was measured 32mm and for the calculation for the load

capacity, we used the ASME equation for threads. Using the following equations:

Note: since the ASME equation was designed for English units we converted all S.I

units to English units.

FL =

Where A = * +Dp = Dm -

H

H = tan 60 (P/2)

P = 1/5

Dm = 1 inch

P

Dm

Fig. 3.9: Shaft Thread


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H = tan 60 (/2) =

Dp = 1.25 - = 1.12 in

Dp = 1.12 in

A = [ ]

= 0.8742 in

2

Convert 0.8742 in2

to S.I unit

A =0.8742 in2x = 564.03 mm2

The factor of safety to be used according to ASME equation reference is 1.25 and tensile

strength of stainless steel was 550N/mm2.

FL = ( ) = 248 173.2 N

Since Fjack= 147 150 N

and 248 173.2 N > 147 150 N

Since the thread load capacity was greater than the force produced by the jack, we therefore

conclude that it was allowable to take the 15 ton hydraulic jack force. Also, according to our

research the nut that can be used for the thread must have a higher tensile strength than the

material of the thread. We used a high tensile nut having a tensile strength of 930MPa which was


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acceptable since it had an allowed tensile stress was higher than the tensile strength of stainless

steel which was 550MPa.

7. Design consideration for Press Frame Stand

The stand was simply discussed in this section since its only purpose was to

elevate and hold in place the press frame. Using angle bars with dimension 1 x 3/16

for the construction. The press frame measures a height of 610mm or roughly 2 feet

from top plate to base plate. We used the stand to elevate the working space where

the operator has easy access on the operation of pressing. The elevated height that the

proponents used for the stand was 545mm to give a total height of press of 1200mm

or 4ft. The stand was forced as an A-frame to prevent bending, the preferred angular

presentation from the ground is 75 Therefore, using a free body diagram, wecomputed the length angle bar to be cut.

15

R 545mm R = = 564.23mm

75

Figure 3.10 Free Body Diagram for Stand Frame Leg

75


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15

362.35mm 300mm x = = 73.02mm

Length of joint bar a = 300mm + 2(73.02mm) = 446.04mm

Figure 3.11 Free Body Diagram for Stand Frame Braces

545mm

75

Fig. 3.12: Stand Frame


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8. Design consideration for Pre-heater

The proponents decided to buy a heat band that would have a temperature control

range from 0-100oC since we need to heat the pressure chamber at 50

oC, 60

oC, 70

oC.

The diameter of the heat band must also fit the diameter of the chamber therefore the

diameter of the heat band is 170mm and the length must not cover the holes of the

pressing chamber, so we concluded 76mm is the length. The available temperature

controller range from 0-300oC and was analogue. The available heat band had the

following parameters 1200 watts and 220 volts. No further computation has been

made since we are only focusing on reaching the desired temperature range and the

time for pre-heating depends on the temperature controller performance.

170mm

76mm

Fig. 3.13: Heat Band


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9. Design consideration for Electric Control Box

a. In the event of electrical malfunction of the band heater controller, we decided to put

up a control box in order to have a safety switch in turning on and off of the thermo-

controller. Shown below was the circuit diagram that the proponents have created.

Figure 3.14: Control Box Diagram for Pre-heater System

In the diagram above, there were five component of the pre-heater circuit. First,

the source of the electricity was from the electric plug where it was inserted to normal

household electric socket holding a 220V capacity. The wire then goes to the power

switch terminal where we considered the three phase switch since it has a safer control on

power than household switches. The two wire from the plug was connected to both side

end of the power switch terminal. A wire connected from the left end of the power switch

terminal that was then connected to the temperature controller terminal P. At terminal 2


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from the controller a wire is connected to a 220V pilot lamp and the other end of it was

then connected to the one of the heat band terminal. The other terminal of the heat band

was then wired to connect at the right side of the power switch terminal. The operation

goes when the plug was inserted to the power source then by pressing ON of the power

switch the electric current will flow into the heat band and the temperature controller.

The temperature was based on the temperature rating adjusted using the temperature

controller. Once the temperature rating was turned on, the pilot lamp will be lighten up.

When the desired temperature was accomplished, the temperature controller cut off the

current flow and the pilot lamp turned off. To turn off the circuit, just press the OFF

switch at the power switch in cases of circuit malfunction of the temperature controller.

The box was dimensioned depending on the sizes of the electrical parts whereas

the suggested dimension is 300mm x 140mm x 65 mm. and holes were drilled according

the alignment of the parts

.

Fig. 3.15: Control Box


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Figure 3.16: Control Box Design

10.Design consideration for Oil Canal.

In order to prevent oil spillage, the proponents designed a stainless steel canal

surrounding the pressing chamber. Since the flow rate of the oil was slow, we

designed the canal wall to be 45mm tall and a diameter of 240mm and then centered

at the mid-point of the pressing chamber. A hole was also drilled to the base plate

inside the canal wall having a diameter of 25.4mm, a nipple steel tube and coupling

tube was attached to the base plate as the exit tube. Note that the hole with the nipple

tube is the outlet for oil where a bucket will catch the drops of oil. An oil brush was

also necessary for us to be able to sweep all oil content extracted during the process.

O

OF

Thermo-controller

Pilot Lam

IN OUT


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45mm

25.4mm

Base Plate

Oil Canal Wall

Exit Tube

Fig. 3.17: Oil Canal and Exit tube Set-up


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3.5 Details of the Prototype

During the design phase of the proposed hydraulic press, the proponents made a

visualization of the prototype by means of using AUTOCAD 2012 Software Application. The

model created in the AUTOCAD provided as a basis for the fabrication of the parts and assembly

of the prototype.

Figure 3.18: Front View CAD Presentation of Hydraulic Press for Jatropha Seed Oil Extraction


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Figure 3.19: Isometric View CAD Presentation of Hydraulic Press for Jatropha Seed Oil

Extraction

Spring Holder

Top Plate

Press Frame Pillar

Spring

Hydraulic Jack

Hydraulic Jack Plate

Press Chamber

Pre-heater

Oil Canal

Base Plate

Stand Frame

Control Box

Oil Exit Tube


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3.6 Design Specification

Hydraulic oil press for jathropa oil extraction

Size = 480mm x 460mm x 1200mm

Hydraulic Jack = 15 ton

Pressing Chamber = , Pillar size = Base plate = Jack plate = Top plate 1 = Top plate 2 =

High Tensile Spring = outside diameter-35 mm, wire diameter5 mm,

Free Length = 200 mm

32mm Nut = 8 pcs

High Tensile spring holder = , 8 pcsHeat band = , 1200 watts , 220VControl Box = 300mm x 140mm x 65 mm


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3.7 Construction Procedure

This section explained how the prototype was constructed in the EMEM Machine Shop

in Balibago, Sta.Rosa City. Using a lathe machine, hacksaw, drilling machine, acetylene welding

machine and an arc welding machine, they succeeded in the construction of the proposed

hydraulic press.

1. First we measured the length of the stroke of the jack piston. After determining the length

required for the press they cut the stainless steel shaft using, a grinder, into four 850mm

in length,

2. Using a lathe machine the machine shop operator was instructed to create threads on both

sides of the stainless steel shafts.

3. When threading was completed, the three 300mm x 300mm steel top plate was drilled in

order to provide a hole fitting the diameter of the thread along with the single plate with

400mm x 400mm x 19mm dimensions. However, we instructed the operator to increase

the hole for the jack plate to provide ease in its movement where the pillars acts also as

its guide post.

4. After drilling holes for the guide post, we instructed to drill 6mm holes for the spring

holder the spring holder is constructed using a threaded rod and welding a rigid nut to it.

Eight spring holders were created along with the four holes on the jack stand plate and

four holes on the top plate.

5. For the construction of the piston or the pressing tool, we instructed the machine shop

operator to cut 70 mm thread steel rod and another 70 mm stainless steel shaft, both

having a diameter of 32mm. Later, we instructed to thread the stainless steel shaft

opposite to the thread of the thread rod with 65mm thread depth. A mild steel shaft


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having a diameter of 76mm and a length of 120mm was holed using a drill machine with

a diameter of 30mm. It was then thread from both ends with opposite direction to each

thread, the length of thread at each end is 50mm. At the center, four holes with 40mm

diameter was drilled which later will act as the hole for the adjuster rod. Two circular

plates is cut from the 10mm steel plate having a diameter of 160mm. One of the plate is

welded to the stainless steel plate and the other at the threaded rod. The upper circular

plate is holed with 10mm at four sides, later this would act as the hole for the bolts that

will attach it to the jack plate. An additional holder was also welded to the press head for

easier adjusting of the press body.

6. Next was the construction of the pressing chamber or the perforated cylinder. Using the

acquired 170mm steel pipe, we advised the operator to cut a length of 160mm and drill

holes of 5mm in diameter with 20mm x 40mm clearance to hole. The total holes drilled

holes were 80.

7. Next was the base plate, a stainless steel plate with thickness of 3mm was welded with

the plate and four holes were drilled on it having the same size as of the top plate.

8. Another hole with size 28mm was drilled to give space for the drain pipe. The drain pipe

was composed of a nipple and a coupling and is welded to the 28mm hole.

9. When the stainless steel plate was welded, the press chamber was aligned to the center

and a guide plate was welded along the half circle at the bottom of press chamber. This

prevents the wiggling of the cylinder.

10.Next is the canal wall having a circumference of 625mm and a height of 25mm which is

welded to the base plate to form a circle large enough to prevent the oil flow to scatter out

from the plate.


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11.A hole is 30mm diameter was drilled to the base plate 50.8mm from the cylinder tube. On

the hole, the 25.4mm nipple tube and 25.4mm coupling tube, made in Thailand, were

welded to it. This will act as the oil hole where it flows down to the catch basin.

12.Locally available parts were bought in the supply stores in order to complete the

prototype such as eight 31.75mm high tensile nuts for the pillar thread and four jst13

springs used for truck brakes assembly.

13.The last part that was constructed was the stand. Using the shape of an a frame, we

instructed the machinist to cut four 50mm x 5mm angle bar with a length of 363mm and

four 50mm x 10mm x 393.78mm to be welded as the stand of the press.

3.8 Material Selection

Our idea in material selection is to be eco-friendly and economically smart. The

proponents selected all the materials from the various sources but we first considered the surplus

shops and junk shops to look for available materials such as steel plates, stainless steel shafts,

steel tube and angle bars, this way we can be able to save a lot in buying materials unlike in

buying on industrial steel supplies where there are no available small cuts to be obtained and

rather buying a full length of each material where it cost a lot more. And If ever we bought brand

new materials, most of the unused portions of the materials will be junked. So to prevent over

spending, we first approached the CRC surplus shop and Balibago, Sta. Rosa City junkshops.

The bolts, nuts and springs were brought brand new since most of the steel materials on

the junkshops and surplus shops were rusted. We considered getting all the bolts, nuts and


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springs from the screws and bolts store in Platero, Binan City along old national road hiway and

in Parian, Calamba along the old national road hiway.

The band heater was bought in Tondo, Manila from the company Heatwave which we

found in sulit.com.ph. The other electrical parts were bought in Ohms electrical shop in Platero,

Binan City.

Since it came from a second hand and junkshops, we carefully selected all usable and

presentable parts available.

3.9 Actual Prototype

TOP PLATE

HYDRAULIC JACK

PRESS TOOL

Pre-Heater

PRESSURE CHAMBER

CONTROL BOX

STAND FRAME


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3.10 Material Costs

Press Frame

Table 3.3: Press Frame Cost

Item Description Cost,Php

Steel Pipe 406

Stainless Steel shaft , 3 meters 2250

Shaft Nut , 8 pcs 475

Spring , 4 pcs 1320

Steel Plates , 5 pcs 1370

Threaded Rod , 4 pcs 96

Rod Nut, 4 pcs 22

Spring Nut Holder, 8 pcs 30

Angle Bar 450

Machine Shop Labor 4000

Miscellaneous 1500

Total Php 11,919


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Pre-heater

Table 3.3 Cooker and Controller Cost

Item Description Cost,Php

Heat Band 900

Temperature Controller 800

Power Switch 125

Royal Wire , 3ft 270

Plug , 10A 40

Control Box 250

Machine Shop Labor 500

Miscellaneous 150

Total Php 3035

Hydraulic Jack, 10 tons= Php 900

Total Cost = 11, 919 + 3035 + 900 = 15854

Jathropa Seed = 30 pesos per kilo


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3.11 Assembly Procedure

Note: Always make sure to wear protective gloves in order to prevent cuts and bruise during

assembly of the press.

1. Insert the pillars into their designated holes in the base plate.

2. Fit in the nut at the bottom thread of the pillar; adjust the nut until it has a righttightness on the base plate.

3. Insert the pressing chamber in the middle of the base plate.

4. Insert the jack plate unto the pillars. Then install the 4 spring holder unto the holes

located near the guide holes.

5. Attach the top plates and tighten the remaining four nut. Also install the springholders into the top plate.

6. Install the springs to the spring holder adjust the nut until the jack plate is levelled.

7. Attach the pressing tool below the jack plate. Insert the flat lead screws to hold the press

tool in the place.

8. Insert the heat band to the pressing chamber. Make sure that the mercury tube is faced in

front of the control box. Then attached the two wires at the electric terminal of the heat

band.

3.12 Press Operation

1. Always wear protective work wear and protective gloves before operation.

2. Check first that the thermo-controller is turned off or to zero. And check that jack piston

is not elevated. Turn on the power switch starting position or non-lifting position.


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3. Insert the ground seed in the pressing chamber.

4. Turn the controller to desired temperature and pre-heat for until the indicator lamp turns

off. Turn off the power switch.

5. Tighten the jack valve and adjust the press tool. Make sure it is aligned flat to the crushed

seeds. Start pumping the lever at the hydraulic jack.

6. Continue pumping until the oil is released from the pressure chamber.

7. Using an oil brush sweep the oil into the outlet hole. Continue sweeping until there is still

oil left from the base plate.

8. After oil is recovered rotate the jack valve slowly from turn counter-clockwise up to 1

turn and wait until the piston is lifted from the pressure chamber. Never attempt to release

the valve quickly since it is dangerous to do so and it may affect the oil seal in the bottle

jack.

9. Remember to check the volume of oil recovered in the basin. Make sure to put it into

another container when 75% full.

10.Remove the thermo-tube from the heat band and carefully remove the pressing chamber

from the press frame.

11.Using a cake bucket and a rigid shaft hammer, pound the cake for removal.


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3.13 Maintenance

The hydraulic jack should be well maintained so that it will function properly and

avoid/prevent efficiency loss.

Most of the parts of our prototype were made of metal which are highly corrosive.

Corrosion monitoring gives vital role for maintenance. Scheduled inspections for corrosion

damage feature prominently to facilitate these pre-emptive actions. The aim is to minimize or

eliminate unnecessary maintenance and inspection activities and to focus maintenance efforts

when and where they are most needed. Moist and wet areas can start to rust the press so it should

be kept away from these areas.

The main part of our prototype is the hydraulic jack. The hydraulic jack is the prime

mover that presses the seeds to produce oil. The exterior of the hydraulic must be always kept

clean because keeping it clean not only removes debris but can identify if any oil comes out from

the cylinder. The ram should be always kept inside the body when not in use because the

unprotected surface can be prone to rust and corrosion. If rust begin to form, gently work the

surface with a piece of emery cloth.

When filling oil any hydraulic jacks, use only approved hydraulic jack oil because

inappropriate oil will cause malfunctioning of the hydraulic jack. The screw plugs, located on the

square metal base of the jack, is the oil fill plug. Never use the brake fluid in place of approved

hydraulic oil because it contains alcohol that will quickly ruin the internal seals.

Most damage occurs by exerting force on an item too heavy for the hydraulic jack s rated

capacity. Exceeding the force capacity can place excessive pressure on these materials, not only

will damage occur in the seals and valves but injury may result to the operator from the jack s


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failure. Springs should also be checked on its proper deflection/stress. Too much load and

elongation of the spring can cause damage the spring itself and may also cause injury and harm

the operator.

The cloth use as bag for the jatropha seeds should always be kept clean so that oil will

come out freely. If the cloth was already worn-out or damaged, have a new one because press

cake will be mixed to the oil.

Documents

Chapter 3 - Hydraulic