DESIGN AND FABRICATION OF A DUAL-PURPOSE WASTE GLASS PROCESSING MACHINE

ABSTRACT

This research focused on the design and fabrication of a dual-purpose waste glass processing machine, using specific design considerations, design theories and calculations, to improve the efficiency of processing of 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 upgrade the waste glass. The isometric projection 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 thickness of 4mm, length of 150mm, height of 150mm and total of 4. The shaft has a length of 530mm, height of 30mm and thickness of 30mm. The eccentric shaft has a length of 650mm and thickness of 30mm. The hammer mill has a length of 140mm, breadth of 35mm, thickness of 2mm and total of 18. The pin has a length of 240mm, thickness of 15mm and total of 2. The spacers have a length of 20mm and are 24 in total. The perforated screen has a length of 450mm, width of 250mm and thickness of 4mm. The sieves 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 of 320mm. The collector has a length of 320mm, height of 35mm and width of 285mm. The housing case has two compartments, the first compartment has a length of 25mm, height of 15mm, width of 30mm; while the second compartment has a length of 250mm, height of 250mm and width of 520mm. Electric motor bed has a length of 450mm, height of 5mm and width of 350mm. The machine has a length of 996mm, 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 an orange colour. The waste glasses were collected from different locations in Ahmadu Bello University Zaria, Samaru main campus. The beneficiation process of the waste glasses involved sorting, soaking, washing and drying. Each of the waste glasses were weighted to 2300g, and were used to test run the dual-purpose waste glass processing machine. The performance of the dual-purpose waste glass processing machine was tested using the sieves of 4mm, 3mm, 2mm and a collector. The results of the processed waste glass were determined by the grain sizes retained on each sieves. The total weight of the flint processed glass retained on the sieves and collector was 2288g, while the total weight of the amber and green processed glasses are 1822g respectively. The grain sizes retained on 4mm and 3mm sieves can be use for glass melting. The grain sizes retained on green, amber and flint glass 2mm sieve can be used for surface texture design. The grain sizes retained on the collector can be for partial replacement of cement, glass paint and glass tiles. The sieve analysis was carried out to determine the grading of the waste glass for use as aggregates.

CHAPTER ONE

INTRODUCTION

1.1         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. Pre-consumer cullet is the 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 all 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). According to Garkida (2007), waste glass are non-degradable making them even more hazardous when they litter the environment especially to children whose only playgrounds are these refuse areas in a country with poor health care system. The need for safe disposal and the search for utility for unwanted glasses cannot be over emphasized, in order to stimulate a reduction of health risks and the conversion of waste to wealth.

Recycled glass must meet quality standards to ensure it can be marketed and made into new glass products. Contaminants must be kept out of glass recycling articles. Contaminants such as ceramics, glass metal rings, and caps cause problem in the recycling process. Ceramics, for examples, have higher melting temperature than glass, when mixed with recycled glass in the melting furnace; the ceramics pieces get embedded in the new glass, resulting in defective and unacceptable new glass products. Metal contaminants remaining in the molten glass also result in depictive and unacceptable new products (Jekada, 2013).

In Gonah (2001), crushing and grinding machines must be designed to exert either pushes or pulls on individual particles, since there are no other kinds of mechanical forces, and that the solid particles must be so introduced into and maintained in the force zone that the forces available can be applied to them. A crushing machine must not only break the materials but, must provide means for continuous representation of uncrushed materials to the crushing zone and continuous discharges of crushed materials therefrom.

1.2         Research Problem

Waste glass is one of the major sources of problem in waste management in Nigeria. The use of waste glass in free blowing and casting was due to high cost of fluxing and fining raw materials (Gonah, 2001). The waste glass processing machine at the Department of Glass and Silicate Technology uses 3 phase and set of sieves are not incorporated into it. The procedures for upgrading and grading of the glass waste are collection, washing, magnetic separation, crushing and sieving respectively. The particle sizes of the cullet which stemmed from the upgrading and grading are used in different applications like melting, casting, partial replacement of sand in concreting, ceramics glazing, surface texture design, and partial replacement of cement. However, the processes of upgrading and grading require two or more machines, which add to the cost of production. Therefore, a dual-purpose waste glass processing machine is imperative to reduce the cost of production.

1.3         Aim

The aim of this research was to design and fabricate a dual-purpose waste glass processing machine.

1.4         Objectives

Objectives of the research were to:

1. design a dual-purpose waste glass processing machine
2. fabricate the dual-purpose waste glass processing machine
3. test run the dual-purpose waste glass machine using the waste glass

1.5         Significance of the Study

Glass can be processed over and over again without the quality deteriorating. Separating and processing glass could significantly reduce waste management costs. The amount of energy needed to melt recycled glass is considerably less than that needed to melt raw materials to make new bottles and jars. Some companies are realizing cost savings by implementing their own processing programs. Processing all the waste glass we throw away would create new jobs for the unemployed by selling the processed glass. Glass processing machine helps in crushing waste glass properly to save time and energy, instead of using stones.

1.6         Justification of the Study

Department of Glass and Silicate Technology are in need of technological equipment; so the availability of a dual-purpose waste glass processing machine will boost the working processes of the glass industries in the country. Waste glass is useless until when graded by crushing into desired size known as cullet, which is not only added to glass melt, but the cullet as raw materials in other industries, particularly building and construction work (Gonah, 2001). For the manufacture of any glass, a poor sieving of glass making raw materials results in defects in the glass production process and reduces the overall quality. Vibrating sieving machines are widely used for grading and screening materials for fast processing. Magnets can pick up magnetic items such as nails, needles, bottle crowns that are either too small for the eye to see during sorting. Magnets can be used in waste operations to separate magnetic metals such as iron, cobalt, and nickel from non-magnetic metals such as aluminum.

1.7         Scope of the Study

The research covered the design using software known as solid works, fabrication using mild steel in old Panteka, Kaduna and the test running of the dual-purpose processing machine with waste glass that was sourced from different locations in Ahmadu Bello University, Zaria, Samaru Main Campus. This research covers only crushing of waste glass and not complete comminution.

Related Project Topics :