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The Optimal performance and operational parameters of a waste plastic plant for crude oil recovery was determined using Response surface method. The operational parameters of the machine investigated include temperature of the reactor, waste plastics in the reactor chamber, catalyst and water flow rate. While volume of recovered crude oil, time required for proper melting and vaporising the waste plastics and time required to properly condense the vapourised crude oil constitutes the performance parameters. The interactions of these factors (operational parameters) and responses (performance parameters) were evaluated and estimated using full factorial design while desirability function approach was the optimization technique applied. The study revealed the reactor temperature (T), quantity of waste plastics (Mp), quantity of catalyst (C) and water flow rate (Q) of 370oC, 5kg, 2.5kg and 4lit/min respectively as the optimal operational parameters of the waste plastic plant for crude oil recovery. While the performance analysis showed that the waste plastic plant with the quantity of recovered crude oil (Vc), time required to completely vaporize the plastics (tr) and total time required to condense the vaporised oil (tc) of the plant were 4.29liters, 41.94mins and 16mins respectively at the optimal factor setting.

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2016

American Journal of Engineering Research (AJER)

e-ISSN: 2320-0847 p-ISSN : 2320-0936

Volume-5, Issue-8, pp-98-104

www.ajer.org

Research Paper

Open Access

J.E. Igwe and C.S. Agu

Department of Mechanical Engineering, College of Engineering and Engineering Technology, Michael

Okpara University of Agriculture Umudike, Abia

ABSTRACT: The Optimal performance and operational parameters of a waste plastic plant for crude oil

recovery was determined using Response surface method. The operational parameters of the machine

investigated include temperature of the reactor, waste plastics in the reactor chamber, catalyst and water

flow rate. While volume of recovered crude oil, time required for proper melting and vaporising the waste

plastics and time required to properly condense the vapourised crude oil constitutes the performance

parameters. The interactions of these factors (operational parameters) and responses (performance

parameters) were evaluated and estimated using full factorial design while desirability function approach

was the optimization technique applied. The study revealed the reactor temperature (T), quantity of waste

plastics (Mp), quantity of catalyst (C) and water flow rate (Q) of 370 oC, 5kg, 2.5kg and 4lit/min respectively

as the optimal operational parameters of the waste plastic plant for crude oil recovery. While the

performance analysis showed that the waste plastic plant with the quantity of recovered crude oil (V c), time

required to completely vaporize the plastics (tr) and total time required to condense the vaporised oil (t c) of

the plant were 4.29liters, 41.94mins and 16mins respectively at the optimal factor setting.

Keywords: Crude oil, response surface, optimal performance, factorial design and plastics.

I.

INTRODUCTION

Plastics play a significant role in the environmental, societal and economical dimensions of

sustainable development [1]. Plastics are light, durable, clean and versatile and therefore have been

increasingly used to make packaging, automotive, building, electronic and electrical products. If we use other

materials to replace plastics, the cost and environmental impacts will more likely to increase. For example,

Americans use 100 billion plastics bags a year, made from about 12 million barrels of oil; instead, the use of

10 billion paper bags each year means cutting down 14 million trees [2]. The use of crude oil for producing

plastics consumes a scarce resource (energy) but the use of paper means the reduction of the capability of the

planet earth to absorb CO2.

Plastics have become an indispensable part in todays world. Due to their light weight, durability,

energy efficiency coupled with fast rate of production and design flexibility, thus plastics are employed in

entire industrial and domestic areas.

Plastics are composed primarily of hydrocarbons but also contain additives such as antioxidant,

colorants, and other stabilizers. Disposal of the waste plastic, poses a great hazard to the environment and

effective method has not yet been implemented. Plastics are slowly biodegradable polymers mostly

containing carbon-hydrogen, and a few other elements like nitrogen. Due to its non-biodegradable nature the

waste plastic contributes significantly to the problem of waste management. Today about 129million tonnes

of waste plastic are produced annually all over the world at which 77million tones are produced due to

economic growth, and consumption change and also the pattern in which things are being produced has

resulted into rapid increase in the production of waste plastics in the world.

Due to the incremental of generation of waste, plastic are becoming a major stream in solid waste.

After food waste and paper waste, plastic waste is the major constituent of municipal and industrial waste in

the cities. By converting plastic waste to fuel, we solve two issues, one of the large plastic seas and the other

of the fuel shortage. This benefit though would exist only as long as the waste plastic lasts, but will surely

provider a strong platform for us to build on a sustainable, clean, and green future. The conversion of waste

plastic into fuel depends on the type of plastics to be targeted and properties of other waste that might be used

in the process.

Recognizing the importance of plastics and the fact that plastics are made of scarce resources, there

have been a lot of efforts in research and development to make plastics reusable and recyclable. According

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2016

[3], the UK government has set out to achieve 45% recycling target by 2015. In 2008-09, 27.3 million tonnes

of municipal waste was collected by UK local authorities but 50.3% was sent to landfill, 36.9% was recycled

or composted, 12.2% was incinerated for energy recovery [4]. Despite knowing that plastics are difficult to

be degraded naturally, UK is throwing away four plastic bottles out of every five [7]. There appears to be a

lack of emphasis and research on the management of the end-of-life (EOL) of products made of plastics and

other scarce resources. There are a lot of research efforts in many different disciplines attempting to find

technologies and ways to make a cleaner and sustainable world. From a simple question such as the use

plastic or paper bags for shopping in the supermarkets to the more complex questions about the most

sustainable approaches to design, manufacture, distribute, and recycle a product, more research is required to

help logistics and supply chain managers to make informed decisions. The trouble is that most of the research

efforts are carried out in isolation without a cradle-to-grave or life-cycle approach. Even though recycling

is believed to conserve materials and reduce greenhouse gas (GHG) emission, recycling activities involve

transportation and production activities which consume energy and natural resources and simultaneously

produce emissions/pollutions. Without understanding of the environmental impacts of recycling logistics

systems, managers will not be able to make better decisions on product design, production, distribution,

choice of materials, and the design of recycling logistics systems. Understanding of the environmental impact

of various logistics solutions for managing product life cycle including product end-of-life (EOL) is a crucial

step towards a cleaner and sustainable world.

Plastic have woven their way into our daily lives and pose a tremendous threats to the environment,

over a 100million tones of plastic are produced annually worldwide, and the use products have become a

common feature at over flowing bins and landfills though work has been done to make futuristic

biodegradable plastics, there have not been many conclusive step towards cleaning up the existing problems.

Here the process of converting waste plastic into value added fuels is explained as a viable solution for

recycling of plastic. Thus two problems such as problem of waste plastic and problem of fuel shortage are

being tackled simultaneously. The waste plastics are subjected to deploy merisation, pyrolysis, catalytic

cracking and fractional distillation to obtain different value added fuels such as petrol, kerosene, and diesel,

lube oil, furnace oil fraction and coke.

The main purpose of this project is to improve the performance of the existing crude oil recovery

plant from waste plastics using Response surface method to minimize total reaction time and maximize crude

oil recovery.

II.

The materials used in the test include: waste plastic to crude oil converter, waste plastics, catalyst,

thermometer, and bucket filled with distilled water with a control valve, hose, and a beaker.

The plastic waste converter consists of two distinct units; the cooking pot/reactor and the condenser

unit. The cooking pot has a feed gate which is the inlet in which the waste plastic is feed into the machine,

and also an outlet to discharge off the residue.

The cooking pot also comprises of a heater which heats up the plastic inside the pot. The cooking

pot is been connected to a condenser via the steam tube where the vapour is been condensed into liquid.

2.2 Data Analysis Procedure

The choice of the type of experimental design was based on the number of variables available (i.e.

number of independent and dependent variables), availability of resources, source of data collected, available

time and cost implication. The effects of four operational parameters on three performance indicators

were studied. The independent variables were coded using the transformation equation given in equation 1

according to [5].

Xi =

(1)

Where is the independent variable in natural factor, is the independent variable in coded factor, Xlow

and Xhigh are respectively the minimum and maximum values of the independent variables and. Two-level

full-Factorial design is used in this study basically for its economic viability as it permits the analysis of a

marginally small number experimental runs from a high factorial point.

The factorial design was generated using MINITAB to first of all, develop a first order model for the

factors under study. This shows that the responses are individually functions of the factors as follows;

Ym = X1, X2,..Xi+

(2)

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2016

Where, Y represents the responses in actual (natural) form, m is the number of responses in the

design, X represent factors in coded forms and i is the number of factors in the design and is the error in the

design. Since four factors were considered in this study, the number of experimental run is given by;

n = 2k

(3)

For a two-level factorial design with a single replicate and no center point, k is the number of

factors, the number of experimental runs therefore is. The two-level first order factorial design was analyzed

with the aid of MINITAB. This design is completely randomized, with both single replicate and block. The

analysis gave rise to a first order regression model of the form;

y = oi + 1 X1i+2iX2i +..kiXki + i

(4)

Where I = 1,2,3,n

Using MINITAB software, the analysis of variance (ANOVA) of the design was conducted to check

the model adequacy to fit the measured data. If the calculated value of exceeds the tabulated value, that is, ,

the fitted models are said to be adequate approximations of the data. The coefficient of determination (R 2)

and adjusted coefficient of determination (adj-R2) for each response models were determined using

MINITAB, to show how well the estimated models fit the measured data. The values of R 2 lies between zero

& one (i.e.) and as the value of R2 approaches one (1), the estimated model fits the data better. R 2 which is

measured in percentage (%), thus, shows the percentage (%) variation of the estimated data) from the

measure data (The standard error of regression (S) and sum of square of error (SS E) also indicate how closely

the estimated response approximates the measured response. The smaller the value of the standard error and

the sum of square of error, the model, approximates the data better [8].

Normal probability plots of residuals, histogram plots, residual versus fit, residual versus

observational order generated using MINITAB in a four-in-one format are diagnostic plots employed in the

model adequacy analysis of the predicted models. The diagnostic plots which show the distribution of the

residuals in each plot graphically shows the adequacy of the predicted model to fit the measured data well.

When and p-value < 0.05, the corresponding factor is said to be statistically significant for a two-tailed test,

hence = 0.05. The significance of individual factors was also investigated using the main effect plots

generated using MINITAB.

Factor interactions and quadratic effects were further created after the critical evaluation of the first

order models to augment the lapses associated with the first order model. Thus, a second order model of the

form in equation 3.4 and an improved first order models with interactions of the form in equation 3.5 were

obtained for the responses.

Y = o + iXi + jXj + iiXi2+ ijXiXj

(5)

After developing, analysing and validating the improved first order models with interactions for the

response function, 3-D surface plots and contour plots for each of the responses against any pair of factors,

were generated using MINITAB software. The optimal settings of each response and the pair of factors were

visualized on the plots. This method is most suitable when there are only two factors in the design. When the

model comprises of more than two factors, its difficult to estimate exactly the optimal settings of the factors

for a given response. This is because of the prevalence of more than one surface or contour plots with varying

topographies for a given response.

In the bid to obtain a simultaneous solution of the predicted response models, desirability function

approach was adopted. This was achieved using the response optimizer tool embedded in MINITAB. Its an

iterative method which can be used to maximize, minimize, or hit target of the responses. This optimization

was based on the target is best kind [9].

III.

3.1 Results

Table 1: Limits of the operational parameters of the machine

s/n

Factor Description

1.

2.

3.

4.

Quantity of Plastics (kg)

Quantity of Catalyst (kg)

Water flow rate (l/s)

www.ajer.org

Factor symbols

Coded

Actual

X1

T

X2

Mp

X3

C

X4

Q

Factor Values

High (+1)

Low (-1)

370

120

5

1.5

2.5

0.25

4

1

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2016

Parameters

Response Goal

Lower

tc

Minimum

tr

Minimum

Vc

Maximum

Target

15.0

40.0

0.9

Upper

35

192

4.3

Weight Importance

1

1

1

1

1

1

Solution

tc

tr

Vc Composite

Solution x1 x2 x3 x4

Fit

Fit

Fit

1

1 1 1 1 16.5625 41.9375 4.28687

Desirability

0.967848

Run

Order

1

2

3

4

5

x1

x2

x3

x4

1

1

-1

1

1

-1

1

1

-1

-1

-1

1

1

-1

-1

1

-1

1

1

-1

Actual Responses

Vc

Tr

Tc

3.9

68

25

1.35

40

15

0.9

170

18

1.31

53

15

4.02

150

25

Predicted Responses

Vc

Tr

Tc

4.05

68.63

22.13

1.45

41

15.88

1.02

172.13

18.5

1.24

51.88

14.13

4.02

150.5

25.38

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2016

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3.2 Discussion

The application of response surface analysis in describing the relationship between the performance

indicators (responses) of the crude oil recovery plant, its operational parameters (factors) and the

determination of the optimal settings of the parameters involves; Development of appropriate RSM

experimental plan, fitting, selection, optimization of the best response surface function for the response. The

performance indicators of the crude oil recovery plant that were evaluated in this investigation are the

quantity of recovered crude oil (Vc), time required to completely vaporize the plastics (t r) and total time

required to condense the vaporized oil (tc).

The independent factors operational parameters- of the machine under study are the reactor

temperature (T), quantity of waste plastics (Mp), quantity of catalyst (C) and water flow rate (Q) and with X 1,

X2, X3, X4 as their respective coded symbols are the operational parameters. The limits of the operational

parameters which influence the performance of the machine as determined experimentally are shown in table

1.

The adequacy of the estimated models was tested using MINITAB 17 and the standardized residual

plots which includes, normal probability plot, histogram of residuals, residual versus fits and residual versus

observation order as shown in figure 1 to 6 for the quantity of recovered crude oil, total time taken for

vapourization of the plastics, time taken for condensation/liquefaction of the vapourised crude oil. The plots

show that the normal curve approximates along the straight line with little deviations, no or little outliers,

reduced or no skewness, good distribution of residuals and cluster around the mean (zero) line as shown in

the normal probability plot, histogram of residuals, residual versus fits and residual versus observation order

of standardized residual which implies that the models fit the data adequately.

3.2.1 Performance Optimization of the Modified Crude Oil Recovery Plant

The relationship between each of the responses and combination of any two (or pair) of the factors

was represented in the response surface and contour plots generated using MINITAB 17 as shown in the

figures below. Only statistically significant predictors were considered in these plots. The topography of each

of the plots indicates the effect of each pair of factors on each of the responses keeping all others constant.

The contour curves (fig.4-6) were used to visualize the direction of the optimal settings for the predicted

models, deeper colouration indicates region of maximum response and light colouration indicates region of

minimum response with respect to the factors at a time. However, this approach is technically unreliable

when there are more than one intermediate response and more than two factors. So the response surface and

contour plot can lead to unnecessary multiplicity of optimal settings.

A closer look at the shape of the graph (fig. 6) would reveal that some of them for a particular

response indicate maximum optimal region, others show minimum optimal regions while some are

intermediate (i.e. showing saddle points). Therefore, there is need to adopt a method that can define the

optimal settings for all the responses with respect to all the factors simultaneously. The multi-response multifactor optimization of the response models was performed using MINITAB 17 response optimizer capability,

based on principle of Derringer modified Harringtons desirability function approach which provides a

combination of the factor settings that simultaneously optimize a set of responses and defines the best

settings for the solution of set of multivariate objective functions.

The optimization result in Table 2 indicates that optimal setting of the quantity of crude oil, time

required to vaporise the plastics and time required to condense or liquefy the vapourised crude are

respectively 4.49liters, 41.94mins and 16mins respectively. While the approximate optimal values of the

reactor temperature, quantity of waste plastics, quantity of catalyst and water flow rate are respectively

370oC, 5kg, 2.5kg and 4lit/s. The optimization results have been tested to establish the adequacy of the

predicted models as shown in the Table 3.

Using the point prediction capability of the MINTAB software, the quantity of crude obtained, time

required to melt the plastics and the time required to properly liquefy the vapourised crude oil of these

experiments were predicted based on the selected models as shown in table 2. Thereafter, predicted values

were compared with the actual experimental results by computing the residuals and their percentage errors as

shown in Table 3. This table shows that the percentage error range between the actual and predicted value for

Vc, Tr and Tc are as follows; 5.34 to -13%, 2 to -2.5% and 11 to -5.87% respectively. Therefore, the

empirical models developed are reasonably accurate since the results of the confirmation runs (actual values

of the responses) are within 95% prediction interval. The 95% prediction interval is the range in which any

individual value (predicted) is statistically expected to fall into. Thus, the models developed were used to

determine the optimal setting of the plastic waste to crude oil machines performance parameters.

www.ajer.org

Page 103

IV.

2016

CONCLUSION

This study revealed the reactor temperature (T), quantity of waste plastics (M p), quantity of catalyst (C) and

water flow rate (Q) of 370oC, 5kg, 2.5kg and 4lit/s respectively as the optimal operational parameters of the

waste plastic plant used for crude oil recovery. While the performance analysis showed that the waste plastic

plant with the quantity of recovered crude oil (V c), time required to completely vaporize the plastics (tr) and

total time required to condense the vaporised oil (tc) of the plant as 4.49liters, 41.94mins and 16mins

respectively with these optimal factor setting. Conclusively it can be showed that for maximum recovery of

crude oil from waste plastic, the machine should be operated at maximum reactor temperature, maximum

quantity of catalyst and a corresponding water flow rate. Furthermore, this analysis showed that all the

factors investigated influenced the performance indicators of the waste plastic plant for crude oil recovery

significantly.

V.

RECOMMENDATIONS

1. With the optimal factors setting known, manufacturers are encouraged to adopt them when transforming

waste plastics into crude oil.

2. This machine should be adopted and commercialized in order to alleviate the dependence on fossils

fuels.

3. The Federal Government should look into waste plastic to crude oil recovery and erect massive

industries for the processes as an alternative means to fossil fuels.

REFERENCES

[1].

[2].

[3].

[4].

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[6].

[7].

[8].

[9].

Buekens A.G and Huang,H. (1998). catalytic plastic cracking for recovery of gasoline-range hydrocarbons from municipal

plastic waste, Resources conservation and recycling, Vol.23. no.3. pp.163,

Panda, A.K. Singh, A.K and Mishra, D.K (2010) Thermolysis of waste plastics to liquid fuel. A suitable method for plastic

waste management and manufacture of value added products- a World prospective, Renewable and sustainable energy reviews,

Vol.14, no. 1, pp.223, 2010.

Aggarwal M. L, Bansal A.(1998). Robust response surface designs for quantitative and qualitative factors. Commun Stat Theory

Methods 1998, 27:89106.

Atkinson, A., Donev, A. & Tobias, R. (2007). Optimum experimental designs, with SAS. Oxford University Press, ISBN 978-019-929660-6, New York, USA

Buyske, S. and Trout, R. (2009). Response Surface Methodology II. http//www.stat.rutger.edu/buyske/591/lect06

Cornell, J. A. (1990). How to apply Response Surface Methodology, Revised edition. Macmillan Publishers. Pp. 284.

Draper N.R,and Hunter W.G (1996). Design of experiments for parameter estimation in multiresponse situations. Biometrika

1966, 53:525533

Funda, k. (2009). The use of Response Surface Methodology for Prediction andAnalysis of Surface Roughness of AISI 4140

Steel. Materials and Technology 43(2009)5.pp. 267-270

Myers, R.H. and Montgomery, D.C. (2002). Response Surface Methodology:Process and Product Optimization using Designed

Experiments. Wiley- IntersciencePublication, New York.

www.ajer.org

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