PARAMETRIC OPTIMISATION OF GENERATED WASTE PLASTIC FUEL PARAMETERS WITH THE HELP OF TAGUCHI METHOD

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International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 1, Jan-Feb 2016, pp. 172-179, Article ID: IJMET_07_01_018

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ISSN Print: 0976-6340 and ISSN Online: 0976-6359

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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 300o

C-450o C from room

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/currentissue.asp?JType=IJMET&VType=6&IType=7

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:


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



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( oC) 23 22 26

Fire point ( oC) 27 25 29

Cloud point ( oC) Below 2 1 to 3 2.5 to4

Pour point ( oC) -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 ( oC) 24 22 26

Fire point ( oC) 28 25 29

Cloud point ( oC) Below 0 1 to 3 2.5 to 4

Pour point ( oC) -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-to-

noise (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


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



Pie chart for percentage contribution

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%.

75.24

9.09

12.93

2.72

Pie chart for percentage contribution

Catalyst Temperature Time Error


Taguchi Method


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PARAMETRIC OPTIMISATION OF GENERATED WASTE PLASTIC FUEL PARAMETERS WITH THE HELP OF TAGUCHI METHOD