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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
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
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%.
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.