Design And Fabrication of A Dual-Purpose Waste Glass Processing Machine

ABSTRACT

This research focused on the design and of a dual-purpose waste glass processing machine, using specific design considerations, design theories, and calculations, to improve the efficiency of processing waste glass.

Recycling waste glass plays an important role in the grading and upgrading of waste glass in the environment. The post-consumer waste glass pollutes the environment and by processing the waste glass using the dual-purpose waste glass processing machine upgrades the waste glass.

The isometric and orthographic projection showing the major components of the dual-purpose waste glass processing machine were designed using software known as solid works.

The major material used for fabrication was mild steel and other materials used were sourced at Old Panteka, Kaduna State. The hopper has an opening of 420mm by 120mm and a discharge end of 400mm by 100mm.

The separator plates have a of 4mm, length of 150mm, height of 150mm, and a total of 4. The shaft has a length of 530mm, the height of 30mm, and a thickness of 30mm.

The shaft has a length of 650mm and a thickness of 30mm. The hammer mill has a length of 140mm, breadth of 35mm, the thickness of 2mm, and a total of 18.

The pin hasa length of 240mm, thickness of 15mm and total of 2. The spacers have a length of20mm and are 24 in total. The perforated screen has a length of 450mm, width of250mm and thickness of 4mm.

The have a length of 320mm, height of 35mm,width of 285mm and a total of 3. The front door has a length of 390mm and width of320mm.

The collector has a length of 320mm, the height of 35mm, and a width of 285mm. The housing case has two compartments, the first compartment has a length of 25mm, the height of 15mm, a width of 30mm; while the second compartment has a length of250mm, height of 250mm, and a width of 520mm.

The electric motor bed has a length of450mm, height of 5mm, and width of 350mm. The machine has a length of 996mm, the height of 700mm, and width of 696mm.

The assembly of the dual-purpose waste glass processing machine was done by separable (using bolts and nuts) and permanent (by welding) fixed joints.

The dual-purpose waste glass processing machine was sprayed with red oxide and orange color. The waste glasses were collected from different locations in Ahmadu Bello University Zaria, Samaru main campus.

TABLE OF CONTENT

Title Page —————————————————————————————- i
Declaration ————————————————————————————– iii
Certification ————————————————————————————- iv
Dedication ————————————————————————————— v
Acknowledgments —————————————————————————- vii
Abstract —————————————————————————————– viii
Table of Contents —————————————————————————— ix
List of Tables ———————————————————————————- xiv
List of Plates ———————————————————————————– xv
List of Figures ——————————————————————————— xvi
List of Appendix —————————————————————————— xvii
Definition of Operational Terms ———————————————————– xviii
List of Notation and Symbols ————————————————————— xix
CHAPTER ONE —————————————————————————— 1
INTRODUCTION —————————————————————————- 1
1.1 Background of the Study —————————————————————- 1
1.2 Statement of the Problem ————————————————————— 3
1.3 Aim ——————————————————————————————- 3
1.4 Objectives ———————————————————————————– 3
1.5 Significance of the Study —————————————————————- 4
1.6 Justification of the Study —————————————————————- 4
1.7 Scope of the Study ———————————————————————— 5
CHAPTER TWO —————————————————————————— 6
LITERATURE REVIEW ——————————————————————– 6
2.1 Indigenous Technology —————————————————————— 8
2.2 Comminution —————————————————————————— 9
2.3 Crusher ————————————————————————————- 10
2.3.1 Jaw crusher ——————————————————————————- 11
2.3.2 Gyratory crusher ————————————————————————- 12
2.3.3 Cone crusher —————————————————————————– 12
2.3.4 Impact crusher ————————————————————————— 12
2.4 Glass Crusher —————————————————————————– 14
2.5 Steel —————————————————————————————– 14
2.5.1 Properties of steel ———————————————————————– 14
2.6 Sieve —————————————————————————————- 15
2.6.1 Sieve analysis ————————————————————————— 16
2.7 Magnet ————————————————————————————- 16
2.8 Concept of Fabrication —————————————————————– 17
2.8.1 Metal fabrication ———————————————————————— 17
2.8.2 Engineering drawing ——————————————————————- 18
2.8.3 Source for raw material —————————————————————- 18
2.8.4 Machining ——————————————————————————- 18
2.8.5 Forming ———————————————————————————– 19
2.8.6 Welding ———————————————————————————- 19
2.9 Electric Motor —————————————————————————- 20
2.10 Cullet ————————————————————————————– 21
2.11 Production and Manufacturing Processes of Machine ————————- 21
2.11.1 Bearing ———————————————————————————- 22
2.11.2 Shaft ———————————————————————————— 22
2.11.3 Belt ————————————————————————————– 22
2.11.4 Pulley ———————————————————————————– 23
2.11.5 Hopper ———————————————————————————- 23
2.11.6 Machine frame ————————————————————————- 24
2.12 General Machine Design Safety Conditions ————————————– 24
2.14 Design Theory ————————————————————————– 24
2.14.1 Belt drive ——————————————————————————- 24
2.14.2 Spring ———————————————————————————– 27
2.14.3 Mathematical modeling of the vibratory sieve housing ————————– 29
2.14.4 Power needed to drive the threshing drum —————————————– 30
2.14.5 Equivalent twisting moment (Te) ————————————————— 30
2.14.6 Equivalent bending moment (Me) ————————————————— 30
CHAPTER THREE ————————————————————————- 31
MATERIALS AND METHOD ———————————————————– 31
3.1 Materials and Equipment ————————————————————- 31
3.2 Design Considerations —————————————————————– 33
3.3 Design of Components in the Machine ———————————————- 33
3.4 Sourcing for the Materials used for Fabrication ———————————- 44
3.5 Fabrication Processes of the Components of the Dual-Purpose Waste Glass Processing Machine————————- 44
3.5.1 Hopper ———————————————————————————– 44
3.5.2 Separator plate ————————————————————————– 44
3.5.3 Shaft ————————————————————————————- 45
3.5.4 Eccentric shaft ————————————————————————– 45
3.5.5 Hammermill —————————————————————————- 45
3.5.6 Pin —————————————————————————————- 46
3.5.7 Revolving beaters ———————————————————————- 46
3.5.8 Spacers ———————————————————————————– 46
3.5.9 Perforated screen ———————————————————————– 46
3.5.10 Sieves ———————————————————————————– 46
3.5.11 Top cover ——————————————————————————– 47
3.5.12 Front door ——————————————————————————- 47
3.5.13 Collector ——————————————————————————— 47
3.5.14 Housing case —————————————————————————- 47
3.5.15 Electric motor bed ——————————————————————— 47
3.5.16 Machine frame ————————————————————————- 48
3.5.17 Assembly of the dual-purpose waste glass processing machine —————– 48
3.5.18 Painting of the finished dual-purpose waste glass processing machine ——– 54
3.6 Cost Estimate —————————————————————————— 55
3.7 Sourcing and Beneficiation Process of the Dual-Purpose Waste Glass Processing Machine ——————- 56
CHAPTER FOUR —————————————————————————- 57
RESULTS ————————————————————————————– 57
4.1 Working Principle of the Dual-Purpose Waste Glass Processing Machine — 57
4.2 Test Running of the Dual-Purpose Waste Glass Processing Machine ——— 58
4.3 Results of the Process Waste Glass ————————————————– 59
4.4 Design Calculations ——————————————————————— 62
4.5 Findings ———————————————————————————— 67
CHAPTER FIVE —————————————————————————– 68
DISCUSSION ——————————————————————————— 68
5.0 Discussion ——————————————————————————— 68
CHAPTER SIX ——————————————————————————- 69
SUMMARY, CONCLUSION, AND RECOMMENDATIONS ——————— 69
6.1 Summary ———————————————————————————- 69
6.2 Conclusion ——————————————————————————– 69
6.3 Recommendations ———————————————————————– 70
REFERENCES ——————————————————————————- 71
APPENDIX ———————————————————————————— 74

INTRODUCTION

Background of the Study

Waste glass exists in three forms which are off-specification cullet, pre-consumer cullet, and post-consumer cullet. Off-specification cullet is generated as glass producers slowly change the ingredient mix in their giant melting vats and finished glass that breaks at the manufacturing plant.

A pre-consumer cullet is a finished glass that breaks at a bottling or distribution facility. Both of these types of waste glass are reused within the glass plants. Post-consumer cullet consists of the glass bottles or other glass products discarded by consumers after use.

Glass is 100 percent recyclable and it can be melted repeatedly to produce the same product, and the technology for recycling glass is relatively simple and well established (McCarthy, 2015).

The glass produced by different manufacturers differs in both form and chemical composition. The form variations are familiar because glass can be pressed and blown into shapes or in more complicated applications, such as fiberglass or fiber optics.

Although glass can be re-melted and changed from one form into another with ease, a problem arises in separating the glass from other materials in a product (for example; separating the glass in a light bulb from other non-glass components).

Although glasses are composed of silica and sodium oxide (soda ash), the type and quantity of other compounds added vary slightly in different types of glasses.

These differences frequently cause problems in recycling glass because producers of some types of glass have strict specifications for the chemical make-up of any cullet they might use(McCarthy, 2015).

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StudentsandScholarship Team.