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4-Raji JPE 23 No1 - kkdmsl
fliud mechanics (2222222)
جامعة كفر الشيخ
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DESIGN DEVELOPMENT AND PERFORMANCE EVALUATION OF WASTE
PLASTIC SHREDDER
Article · June 2020 DOI: 10/JPE-2020-01-
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Nurudeen Adekunle Raji Lagos State University 59 PUBLICATIONS 172 CITATIONS SEE PROFILE
Rafiu Kuku Lagos State University 9 PUBLICATIONS 32 CITATIONS SEE PROFILE
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doi/10.24867/JPE-2020-01-
JPE (2020) Vol (1) Original Scientific Paper Raji, A., Kuku, O., Ojo, S., Hunvu, M.
DESIGN DEVELOPMENT AND PERFORMANCE EVALUATION OF WASTE
PLASTIC SHREDDER
Received: 02 March 2020 / Accepted: 20 June 2020
Abstract: The conservation of energy and sustaining clean environment had been a focus for attention. Waste plastics releases hazardous substances into the environment. Plastic shredding machine had played considerable role in the waste plastic recycling process towards solving the problem associated with plastic waste and the harvesting of the much energy that the waste plastic could provide for human need. In this paper, a 50 kg processing shredding machine for waste plastics was designed and fabricated. The drive mechanism for the machine combined the belt and gear drives to avoid the deficiency associated with the common single belt drive shredders. The data obtained from the design analysis of the shredder machine was used to fabricate the machine for improve energy utilization of the prime mover through optimizing the design parameters of the drive mechanisms. Performance evaluation of the machine indicates that the machine efficiency is between 90-96 % for the HDPE, PVC and the PET waste plastic. Key words: Plastic, shredder, shaft, frame, cutting blade, belt drive, gear drive.
Razvoj dizajna i ocena performansi drobilice za otpad. Fokus ovog rada je na očuvanju energije i održavanju čiste životne sredine. Otpadna plastika izbacuje opasne materije u životnu sredinu. Mašina za drobljenje plastike ima značajnu ulogu u procesu recikliranja otpadne plastike u cilju rešavanja problema vezanog za plastični otpad i uštedu velike količine energije koju otpadna plastika može da obezbedi za ljudske potrebe. U ovom radu je dizajnirana i izrađena mašina za drobljenje od 50 kg za otpadnu plastiku. Pogonski mehanizam mašine kombinuje pogonske trake i zupčanike kako bi se izbegao nedostatak koji je povezan sa uobičajenim drobilicama sa jednim remenom. Podaci dobijeni konstrukcijskom analizom mašine za drobljenje korišćeni su za izradu mašine za poboljšanje iskorišćenja energije primarnog pokretača kroz optimizaciju konstrukcijskih parametara pogonskih mehanizama. Procena performansi mašine pokazuje da je efikasnost mašine između 90-96% za HDPE, PVC i PET otpadnu plastiku. Ključne reči: Plastika, drobilica, osovina, ram, testera, remen, pogon zupčanika.
- INTRODUCTION
Plastic waste is damaging to the environment and its removal should be a major concern which can be done by recycling. In recent time the hip of non- biodegradable waste plastic is becoming challenging especially in the developing economy like Nigeria. Current disposal methods of the waste plastics especially as landfills had created serious environmental concern which is threatening human health and safety [1]. Pollution resulting from accumulation of the plastic waste especially in the water ways and oceans had been a source of concerns. Although much energy is consumed during the production and manufacture of plastic, the energy value for the plastic manufacture at the end lifecycle is hardly reclaimed. The plastic waste is often used as landfill which more occupies useful spaces. These energies in some plastic products could be reclaimed through recycling. Since plastic products are petroleum based, the rising cost of petroleum as raw material for production and manufacture of plastic could make the consideration for recycling of the plastic waste a profitable and sustainable venture. Management of waste plastic for recycling involves six basic stages; this includes the plastic collection, sorting, washing, shredding, melting, and
pelletizing. The collection procedure in most developing countries presently is done manually by drop-off centers and buy-back centers but the mechanization of the other stages of the recycling process had received considerable research efforts in the past years. The different stages of the recycling process had received considerable attention [2]. The sorting process is the separation of the waste plastic according to their types. The sorting machine designed for this purpose are as discussed in [3, 4], the washing process [5, 6], the melting process [7] and the material pelletizing. The shredder seems to be the major focus of researchers [8- 18]. Design of a plastic recycling machine which combined the principle of conveying and heating to effect shredding and melting of the plastic was however attempted [19], this machine was observed only suitable for domestic plastics of smaller units. Although optimization attempt was done for the heating process, the conveying unit and extrusion for efficient output need be thoroughly analyzed. The desired to package shredded waste plastic for foreign export as may be required for foreign exchange earnings should encourage stand alone shredding operation for such waste plastic management. Plastic shredding is the process of reducing the
Belt drive section views
Helical gear mesh Helical gear mesh end view
Drive pulley
Driven pulley
Feeder drum
Belt direction of motion
Fig. 2. Drive mechanism
Design specification Hours/ day duty 10 Power rating of prime mover, Pn 3 h Rotational speed of prime mover 1440 rev/min Rotational speed of driven shaft 980 rev/min Service factor, Ks 1. Sheave center distance, C 1400 mm Table 1. Operating conditions
Belt selection: The effective operation of the belt drive could depend upon the frictional force between the belt and the pulley, and the elasticity of the belt. This is required for short inter pulley distance as is required for this design. The velocity ratio of the drive assuming negligible slip and creep effect is obtained as in equation (1).
ܵൌ ݅ݐܽݎ ݀݁݁ (1) ni is the rotational speed of the driving sheave, and no is the rotational speed of the driven sheave. The design power could be obtained as expressed in equation (2).
ܲ ,ݎ݁ݓ ݊݃݅ݏ݁ܦ ௗ ܭ ൌ௦ܲ. (2)
The equations (1) and (2) are combined with the manufacturers chat to select the narrow profile A- section (SPA) wedge belt for the design. The results are obtained as tabulated in Table 4 and Table 5. In order to avoid energy waste during operation of the machine, there is need to avoid excessive friction. The belt is pre-loaded with tension ܶ to avoid slippage of the belt on the pulleys. The value of the preload could be obtained as expressed in equation (3).
ܶ2 ܶ ൌ ܶ (3)
Tp and Th are the pull and hold force on the belt respectively representing the tight and slack side belt tension which is obtained equations (4a) and (5). Equation (4) described the belt friction forces between the belt and the pulley surface. This friction is
responsible for the difference in tight side and the slack side tensions of the belt. The frictional force increases with the amount of wrap on the surface of the pulley and is described by the belt Euler equation (4a). ் ் ൌ exp ቆ
ఏ ௌഁ మ
ቇ (4a)
is the belt wrap angle on the driving pulley, is the
coefficient of friction between the belt and the pulleys, and is the pulley groove angle. The belt wrap angle is obtained from equation (4). ݊ ݅ ܵ 2 െ ߨ ൌ ߠ ିଵ ିௗ ଶ (4b) D and d are the pitch diameters of the driving and driven sheaves respectively. The power delivered to the gear drive of the machine is a function of the belt tensions as obtained from equation (5a) as in [24]. ܲ ௗ ܶ൫ ൌ ܶ െ ݒ .൯ (5a) ݒ is the belt velocity obtained as expressed in equation (6). ൌ ݒ గ ݀. (5b) The resultant of the pull and hold forces, ܨோ, is the turning force producing the required torque for the operation of the positive cutting-tool shaft. The resultant force is obtained as defined in equation (6) [25, 26]. ܨோ ܶ൫ ൌ ଶ ܶ ଶ ܶ2 െ ܶ ൯ߠݏܥ ଵ/ଶ (6) The transmission torque is thus obtained as expressed in equation (7). ܯ௧ ܨ ൌோ. ௗ ଶ (7) Gear selection: The gear drive suggested for the machine is the spur gear mesh. The Lewis equation (8a) is used for the selection of the spur gear for the operation. The operation condition of the spur gear is as given in Table 2. ߪ ൌ ௐ ೡி.. (8a)
Specification for the spur gear design
Material for pinion and gear
Carburized hardened steel Permissible bending stress, 144 MPa Rotational Speed of pinion and gear, no 980 rev./min. Power transmitted, Pd 2 kW Gear ratio 1: Number of teeth on pinion and gear, N 22 Module, m 1. Pressure angle, 20 o Lewis form factor, Y 0. Table 2. Operating condition for shredder spur gear
The face width of the gear is obtained from equation (8a) as follows in equation (8b);
ܨ ൌ ௐ ೡ.ఙ.. (8b)
The transmitted load ܹ ௧is obtained as expressed in equation (9).
ܹ ௧ ൌ ௪ ௧௦௧௧ௗ, ௧ ௩௧௬,௩ (9)
The pitch line velocity is obtained as expressed in equation (10)
ݒ ൌ గ ݀. (10) ݀ is the pitch diameter of the gear which could be determined from equation (11)
݀ ൌ ݉. ܰ (11)
The dynamic factor, ܭ௩ is determined from equation (12)
ܭ௩ ൌ ൫ା௩൯ (12) The design values obtained from equations (8) – (12) as detailed in Table 7 could be used to select the appropriate pinion and gear parameters for the design as presented in Table 8. The shaft design: The shaft design include specifying the shaft dimensions for strength and possible fluctuating load integrity considering the shaft bearing supports, the mounted components and the shaft dynamic. The shaft layout is as shown in Figure 3
Pulley Gear Fig. 3. Shaft layout
The shaft consists of stepped sections to accommodate
the bearing mount, the gears, and the sheaves. Keys are provided to assemble the gears on the shafts. The shaft is designed according to the ASME code for ductile material expressed in equation (13), ݀ ଷ ൌ గఛଵ ೌ
݇ඥሺ ሻܯଶ ݇ሺ ௧ ܶ ሻଶ (13)
km is the bending factor accounting for shock and kt is the torsion factors accounting for fatigue in the machine. ߬ is the material yield strength, M and T are the shaft bending moment torsion load respectively. The shaft design is base on the specification as given in Table 3.
Parameters Design load 50 kg Rotational speed of shaft 980 rev/min Power transmitted, Pd 2 kW Bending factor for shock, km 2 Torsion factor for fatigue, kt 1. Allowable Stress, all 40 Mpa Table 8. Design specification The cutter blade design: The 3 ଷ ଼
݄݅݊ܿ݁ݏ circular
saw blade with PV-form teeth and made of solid alloy steel as shown in Figure 4 was adopted for the design. The blades were mounted and rigidly fixed on the positive and negative drive shafts spaced 10 mm on both shafts. The arrangements of the blades are as shown in Figure 4b The machine frame: The grinding machine elements are supported on the frames. The frame design includes the gear mesh housing, the cutting tool enclosure, the hopper and the machine support framework. The frame design was considered for rigidity, size and weight. The frames were fabricated from mild steel plates of 2 mm thickness and the 38 x 38 mm angle iron.. The angle iron support beam was design to resist bending by limiting the deflection due to the loading from the machine elements using the model expressed in equation (14) assuming that the support beam is simply supported. The frame stand is assumed as a column and designed against buckling to ensure that the length of each stand do not exceed ܮ as expressed in equation (15). ߜ ൏ ி
య ସ଼ா ூ (14)
ܮ ටߨൌ ாூೣೣ ி (15) Where F is the force exerted by the machine elements, L is the length of the beam frame, ܮ, E is the Young’s modulus for mild steel, and ܫ௫௫ , ܫ௬௬ are the second moment of area for the beam and column stand respectively.
Test Material
Input Quantity (kg)
Quantity of pellets (kg)
Mean Value (kg)
Efficiency (%)
LDPE 37.
20
22 22 60
25
HDPE 50
44.
46 46 92.
48
PVC 50
47
47 47 94.
46.
PET 52.
50
48 48 92.
48
Table 9. Machine performance result
Machine efficiency % Motor Speed (rpm) LDPE HDPE PVC PET 950 63 90 89 95. 1200 60 92 95 92. 1420 60 92 94 92. Table 10. Efficiency comparison for machine under varying motor speed
The result shows that the machine performance improved at lower speed of operation for the LDPE and the PET materials. The speed of operation of the machine could be specified for the type of waste plastic desired to be shredded. The PET plastic could be shredded efficiently at a speed of 950 rpm compared with the PVC and the HDPE with higher efficiency at 1200 rpm. The variation in the performances of the machine at different speed of operation could be attributed to the excusive disparities in the mechanical properties of the plastic materials.
- CONCLUSION
The plastic shredding machine is a need for plastic waste management. The plastic shredding machine was designed and fabricated. The typical requirement for the design is the machine rigidity, strength, stability and safety of operation. The machine was designed to accommodate an average of 50 kg waste plastic for processing. The performance evaluation of the machine shows that the machine is more effective for shredding of the HDPE, PVC and PET waste plastics. However at a speed of 950 rpm the machine could be use for the shredding of LDPE. The shredder machine could be used for medium scale waste plastic recycling plant where such size of pellet between 2 – 4 mm would be required for processing by an extruder. The machine is readily available and affordable for small and medium scale waste plastic processing plant.
5. REFERENCES
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[21] Okunola, O., Oyebade, D., Olanrewaju, O. (2016) “Development of Shredding and Washing Machine for Polyethylene Terephthalate (Pet) Bottles Pelletizer”. International Journal of Engineering Science and Application, 3(2), 102- 109 [22] Ravi, S. “Utilization of Upgraded Shredder Blade and Recycling the Waste Plastic and Rubber Tyre”. Proceedings of the International Conference on Industrial Engineering and Operations Management Paris, France, 2018, 3308- [23] Tegegne, A. Tsegaye, A., Ambaye, E. Mebrhatu, R. (2019) “Development of Dual Shaft Multi Blade Waste Plastic Shredder for Recycling Purpose”.International Journal of Research and Scientific Innovation, VI(I), 49- [24] Childs, P.R. Mechanical Design. Elsevier Butterworth-Heinemann, Oxford. 2nd edition, 2004. [25] Lubarda, V. (2014) “The mechanics of belt friction revisited”. International Journal of Mechanical Engineering Education, 42(2), 97- dx.doi/10.7227/IJMEE. [26] Lubarda, V., (2015) “Determination of the belt force before the gross slip”. Mechanism and Machine Theory 83 31– dx.doi/10.1016/j.mechmachtheory.2014. 08.
Authors: Nurudeen A. Raji (Associate Professor) Rafiu O. Kuku (Lecturer) Seun S. Ojo (Research Student) Sejero M. Hunvu (Research Stdent) Mechanical Engineering Department, Lagos State University, Nigeria E-mail: nurudeen@lasu.edu
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4-Raji JPE 23 No1 - kkdmsl
Course: fliud mechanics (2222222)
University: جامعة كفر الشيخ
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