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SYNTHETIC FUEL FROM WASTE PLASTIC MATERIALS · PDF fileNI Company provides PID control toolkit...

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SYNTHETIC FUEL FROM WASTE PLASTIC MATERIALS USING LabVIEW M.Rajeshkumar 1 , B.Sudhan 2 , R.Vignesh 3 , M.Vigneshwaran 4 , U.G. Students, Department of EEE, Mahendra Engineering College, Namakkal. Guided by: Dr.S.Umamaheshwari 5 , Prof/Dept of EEE, Mahendra Engineering College, Namakkal B.S.Rajan 6 , Assistant Professor Department of EEE, Mahendra Engineering College, Namakkal I. ABSTRACT Plastics are constantly an immense threat and a growing peril to the environment, since it retains specific distinctive chemical properties, but still there have not been any conclusive steps taken to cease the existing landfills of plastics. Attributable to the substantial production of plastics every year, there are loads of landfills with plastic trashes. In view of the fact that plastics stem from petroleum (crude oil), it is doable to extract the synthetic fuel from plastics by befitting techniques. Numerous technologies are being developed to make use of plastics for obtaining the synthetic fuel. Various thermo chemical processes are existing to obtain fuel grade hydrocarbons from the waste plastic materials. Pyrolysis is the fitting process for the extraction of fuel grade hydrocarbons from the barren plastics. It is necessary to reuse the scarce resources wherein, it is paramount to reuse the petroleum products. The extraction of fuel from plastics amends the depleting petroleum resources and withal aids humanity to maintain the ecological balance. Keywords: LabVIEW- Workbench, Pyrolysis, Landfill, Recycling. II. INTRODUCTION Plastic is one of the most commonly used materials in daily life which can be classified in many ways based on its chemical structure, synthesis process, density, and other properties. In order to assist recycling of the waste plastic, Society of Plastic Industry (SPI) defined a resin identification code system that divides plastics into the following seven groups based on the chemical structure and applications. PET (Polyethylene Terephthalate), HDPE (High Density Polyethylene), PVC (Polyvinyl Chloride), LDPE (Low Density Polyethylene), PP (Polypropylene), PS (Polystyrene). One of the major concerns for extensive use of the plastics is the disposal of the waste plastic. In addition, the plastics are produced from non- sustainable oil or coal, and thus it is a non- sustainable product. Pyrolysis of waste plastic is an economical method to solve waste plastic problem and to produce quality liquid fuel which can have similar properties to the commonly used petroleum fuels. The technology helps to save land resources by utilizing waste plastics to generate valuable energy. Currently, a majority of the waste plastic is land filled and it is not sustainable because waste plastic takes very long time to decay. Pyrolysis of Plastic Materials Pyrolysis is a thermal cracking reaction of the large molecular weight polymer carbon chains under an oxygen free environment and produces small molecular weight molecules. Traditional treatments for post-consumed plastics were landfills or incineration. However, landfill of the post- consumed plastics has potential problems because of limited land resource and high durability of plastics. Incomplete incineration may generate poisonous substances and causes serious health problems. Other methods like gasification and bioconversion are mainly used for organic materials. In these process, catalysts are also used to improve the quality of pyrolysis products. HDPE, LDPE, PP and PS are all hydrocarbons consisting entirely of carbon and hydrogen, which are similar to hydrocarbon fuels such as liquefied petroleum gas (LPG), petrol and diesel. Plastics are derived from petroleum and have calorific values in a similar range as those of LPG, petrol and diesel as given in below Table 1. Table 1: Calorific Values of Different Plastic materials Material Calorific value (MJ/kg) Polyethylene 46.3 Polypropylene 46.4 Polystyrene 41.4 Polyvinyl chloride 18.0 Coal 24.3 Liquefied petroleum gas 46.1 Petrol 44.0 Kerosene 43.4 Diesel 43.0 Light fuel oil 41.9 Heavy fuel oil 41.1
Transcript

SYNTHETIC FUEL FROM WASTE PLASTIC MATERIALS USING LabVIEW

M.Rajeshkumar1, B.Sudhan

2, R.Vignesh

3, M.Vigneshwaran

4,

U.G. Students, Department of EEE, Mahendra Engineering College, Namakkal.

Guided by:

Dr.S.Umamaheshwari5, Prof/Dept of EEE, Mahendra Engineering College, Namakkal

B.S.Rajan6, Assistant Professor Department of EEE, Mahendra Engineering College, Namakkal

I. ABSTRACT

Plastics are constantly an immense threat and a

growing peril to the environment, since it retains

specific distinctive chemical properties, but still

there have not been any conclusive steps taken to

cease the existing landfills of plastics. Attributable

to the substantial production of plastics every year,

there are loads of landfills with plastic trashes. In

view of the fact that plastics stem from petroleum

(crude oil), it is doable to extract the synthetic fuel

from plastics by befitting techniques. Numerous

technologies are being developed to make use of

plastics for obtaining the synthetic fuel. Various

thermo chemical processes are existing to obtain

fuel grade hydrocarbons from the waste plastic

materials. Pyrolysis is the fitting process for the

extraction of fuel grade hydrocarbons from the

barren plastics. It is necessary to reuse the scarce

resources wherein, it is paramount to reuse the

petroleum products. The extraction of fuel from

plastics amends the depleting petroleum resources

and withal aids humanity to maintain the ecological

balance.

Keywords: LabVIEW- Workbench, Pyrolysis,

Landfill, Recycling.

II. INTRODUCTION

Plastic is one of the most commonly used materials

in daily life which can be classified in many ways

based on its chemical structure, synthesis process,

density, and other properties. In order to assist

recycling of the waste plastic, Society of Plastic

Industry (SPI) defined a resin identification code

system that divides plastics into the following seven

groups based on the chemical structure and

applications. PET (Polyethylene Terephthalate),

HDPE (High Density Polyethylene), PVC

(Polyvinyl Chloride), LDPE (Low Density

Polyethylene), PP (Polypropylene), PS

(Polystyrene).

One of the major concerns for extensive use of the

plastics is the disposal of the waste plastic. In

addition, the plastics are produced from non-

sustainable oil or coal, and thus it is a non-

sustainable product.

Pyrolysis of waste plastic is an economical method

to solve waste plastic problem and to produce

quality liquid fuel which can have similar properties

to the commonly used petroleum fuels.

The technology helps to save land resources by

utilizing waste plastics to generate valuable energy.

Currently, a majority of the waste plastic is land

filled and it is not sustainable because waste plastic

takes very long time to decay.

Pyrolysis of Plastic Materials

Pyrolysis is a thermal cracking reaction of

the large molecular weight polymer carbon chains

under an oxygen free environment and produces

small molecular weight molecules. Traditional

treatments for post-consumed plastics were landfills

or incineration. However, landfill of the post-

consumed plastics has potential problems because

of limited land resource and high durability of

plastics. Incomplete incineration may generate

poisonous substances and causes serious health

problems. Other methods like gasification and

bioconversion are mainly used for organic

materials. In these process, catalysts are also used to

improve the quality of pyrolysis products. HDPE,

LDPE, PP and PS are all hydrocarbons consisting

entirely of carbon and hydrogen, which are similar

to hydrocarbon fuels such as liquefied petroleum

gas (LPG), petrol and diesel. Plastics are derived

from petroleum and have calorific values in a

similar range as those of LPG, petrol and diesel as

given in below Table 1.

Table 1: Calorific Values of Different Plastic

materials

Material

Calorific value

(MJ/kg)

Polyethylene 46.3

Polypropylene 46.4

Polystyrene 41.4

Polyvinyl chloride 18.0

Coal 24.3

Liquefied petroleum gas 46.1

Petrol 44.0

Kerosene 43.4

Diesel 43.0

Light fuel oil 41.9

Heavy fuel oil 41.1

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NI-LabVIEW

LabVIEW- Laboratory of Virtual Instrumentation

Engineering Workbench. LabVIEW is an integrated

development environment designed specifically for

engineers and scientists. LabVIEW is a Graphical

programming language (G Language) that uses data

flow model instead of sequential lines of text codes,

empowering to write functional code using a visual

layout.

II. OPERATION

A. BLOCK DIAGRAM

Figure 1: Block Diagram of Synthetic Fuel from

Waste Plastic Materials Using LabVIEW

The waste plastic materials are grinded and feed to

the heating reactor. In heating reactor catalyst is

added to increase the rate of reaction. In heating

reactor, waste plastic materials are converted to

hydrocarbon gas with absence of oxygen at 380-

4300c temperature. Converted hydrocarbons are fed

into the cyclone to remove the unwanted substance

present in it. The unwanted sediment obtained from

the cyclone hurled into the container for the

imminent use. The fuel grade hydrocarbons

required for the conversion process are send to the

gas container while the remaining hydrocarbons are

fed into the reservoir for utilizing during exigencies.

The gas with the fuel grade hydrocarbons are

dowsed by employing the quencher. The overall

process, is controlled and automated by LabVIEW.

LabVIEW and the system is interfaced using NI-

DAQ. The implementation of LabVIEW for

controlling the extraction of synthetic fuel from

waste plastic acts as a curb on the excessive

wastage of plastic materials.

B. HEATING REACTOR

It consists of spherical heating element connected to

electric power supply, a case and optionally a

temperature sensor with hysteresis which is used to

switch the power supply on or off. Such a heating

reactor can be used in connection with the PID

technique in LabVIEW. There are also more

sophisticated heating reactor in the market which

are controlled by microcontrollers but they are not

suitable for the proposed project, since LabVIEW

has integrated PID Module.

C. CYCLONE

Obtained hydrocarbon from the heating reactor is

fed to the cyclone where the unwanted substances

like charcoal, dust particles are removed. The

removed unwanted substances are collected using a

container and dispatched carefully.

D. GAS CONTAINER AND RESERVOIR

The fuel grade hydrocarbons are fed into the gas

containers for processing while the excess

production of hydrocarbons are fed into the

reservoirs. When the hydrocarbons extracted do not

meet the required level of production, the reservoir

will provide the remaining amount of hydrocarbons.

Because of this technique, the production remains

constant and quality of the product remains

constant.

E. QUENCHER

The hydrocarbons are dowsed into fuel with the use

of quencher. The obtained fuel undergoes the hydro

treating process to convert it into standardized fuel.

III. CONTROL TECHNIQUE

A. PID CONTROL

PID control is the combination of proportional

control, integral control and differential control,

thus integrating the advantages of such three kinds

of controllers. In practical application, there is no

need to use all these three parts, but only

proportional control unit is indispensable. For the

PID controller, the output is:

Where Kp= Proportional gain, Ki= Integral gain,

Kd = Derivative gain. Finally we can get a complete

PID control.

PID control actually means setting these three

parameters, namely, Kp, Ti and Td, in order to get

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applicable output value to control the system. The

specific details on how to set them are different

based on different situations. Currently, PID is not

only widely applied but also rapidly developed. The

intelligent controllers which can self-tune these

three parameters have been massively invented.

After the combination between PID and digital

controllers such as computer, the design method of

digital PID has also emerged, whose specific

principle still follows the traditional ones.

A successful operations of automatic control

system requires anti-jamming capability, stability

and ability to meet the given performance index.

Since the physical structure and the working

process of the controlled object are constant, the

output value of a given signal could not meet the

needs of system. Therefore, a controller needs to be

included.

The controller and the controlled object will

form a closed-loop system which helps the output

of the system meet the given performance index.

PID (Proportional Integral Derivative) control is a

widely used control method. It has huge advantage

in the fields of control engineering. PID controller

has simple structure, excellent stability, reliable

performance and convenient adjustability.

PID Modules in LabVIEW

NI Company provides PID control toolkit used in

LabVIEW, which can help engineers quickly and

efficiently build a digital PID controller by

combining with the NI data acquisition device, thus

a complete system acquires accurately and reliably.

Software defined PID modules are shown in figure

2.

Figure :2 PID Modules

IV. SIMULATION RESULT

Simulation of this project demonstrates the working

model of synthetic fuel from waste plastic materials

using LabVIEW and working model shown in

figure 3 and figure 4.

Figure 2: Simulation Control

Figure 3: Simulation Process monitoring

ANALYSIS

Analysis of synthetic fuel from waste plastic

materials process is shown in figure 5.

Figure 4: Analysis of process

IV. APPLICATIONS

Used in the production of petroleum products

like petrol, diesel and kerosene.

Solid waste plastic management system.

Can be used as an alternative fuel in future

V. CONCLUSION

It can effectively reduce the hazardous impact of

waste plastic accumulation on earth. Pyrolysis

process is having higher potential for the conversion

of plastic into fuel. It has been estimated that this

conversion process reduces the CO2 emission by

85%.

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VI. REFERENCE

1) www.pyrolysisplant.com

2) www.ni.com/casestudy

3) “Conversion of waste plastic into a resource”

by Dr. H.H. Shinde, P.S. Sewahkar, Jawaharlal

Engineering College in Volume 6, Issue 3

February 2016 IJIET.

4) “Conversion of plastic wastes into liquid fuels

– a review” by Arun Joshi, Rambir and Rakesh

Punia in Recent Advances in Bioenergy

Research Vol. III 2014.

5) “Preparation of Liquid Fuels From Waste

Plastics” by Avinash Mohapatra, Manpreet

Singh, Department of Chemical Engineering,

National Institute of Technology, Rourkela.

6) “Pyrolysis process” by Biofuels Academy

dedicated to biofuels education in chemical

Engineering

7) “Temperature control in PID controller by

LabVIEW” by Hongji Yu, Bachelor’s Thesis

in Electronics, June 2014.

8) “Designing PID Controller using LabVIEW

for Controlling Fluid Level of Vessel” by

Harsh Kaji, Shruti Annigeri, Prafulla Patil ,

Vidyavardhini‟ s College of Engineering and

Technology, IJERA, Vol. 3, Issue 2, March -

April 2013.

9) “Control System for Chemical Thermal

Processes and Its Usage for Measurement of

Collagen Shrinkage Temperature” by PETR

CHALUPA, MICHAELA BAŘINOVÁ,

JAKUB NOVÁK, MARTIN BENEŠ,

Regional Research Centre CEBIA-Tech, and

Faculty of applied Informatics Tomas Bata

University in Zlin nam.

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