DUST EXTRACTION SYSTEM FOR COMPOSITE MATERIAL

SANJIVANI RURAL EDUCATION

SOCIETY’S, COLLEGE OF ENGINEERING,
KOPARGAON.

(2020-2021)

Fabrication of Dust extraction system for

composite material

Prepared by:
Sr. Name University Seat Number Roll Number
No.

1. Nidan Dinesh Patil 71925286F 200

2. Jayesh Dnyaneshavar 71925275L 190

Mote
3. Aishwarya Bhanudas 71808146D 06
Gadekar

Guided By: Prof. H. P. VARADE SIR

Sanjivani College of Engineering, Kopargaon B.E. (Mechanical) Page 1

 DUST EXTRACTION SYSTEM FOR COMPOSITE MATERIAL

Sanjivani College of Engineering, Kopargaon B.E. (Mechanical) Page 2

 SANJIVANI RURAL EDUCATION
SOCIETY’S, COLLEGE OF ENGINEERING,
KOPARGAON.

(2020-2021)

CERTIFICAT E
This is to certify that,

Mr. Nidan Dinesh Patil Mr. Jayesh Dnyaneshvar Mote

Mrs.Aishwarya Bhanudas Gadekar

Has successfully completed the Project Stage – I entitled,

Fabrication of Dust extraction system for composite material

Under my supervision, in the partial fulfilment of Bachelor

of Engineering - Mechanical Engineering of University of Pune.

Date:
Place: Kopargaon

Prof. H. P. Varade
Guide Internal Examiner

Dr. S.V.Bhaskar Dr. A.G.Thakur

Head of Department Principal
 AKNOWLEDGEMENT

We take the opportunity to express our deep sense of gratitude and sincere thanks for the
guidance and constant supervision as well as for providing necessary information regarding
the project that we have received from our project guide PROF. H. P. VARADE Sir who
helped us a lot.

We would like to express our gratitude towards Dr. S.V. Bhaskar, Head of Mechanical
Department for his encouragement and guidance which help us in completion of first phase of
our project.

Last but not the least, we are grateful to all staff members of Mechanical engineering
department who patiently helped in all possible ways. We are also delighted by the way our
colleagues have supported us. Without support of these fine people this phase of our project
would have not been possible.
 CONTENTS

SR. SUBTITLE TITLE PAGE

NO. NO. NO
1 Abstract 6

2 Introduction 7

2.1 The most common types of centrifugal, or 8

inertial, collectors in use today are
2.2 Problem Statement 9

2.3 Objective 9

2.4 Methodology 10

2.5 Future scope 10

3 Literature survey 11

4 Project plan 14

5 Final design and main component 15

5.1 Electric motor 15

5.2 Cyclone separator 16

5.3 Wheels 16

6 Calculations 20

7 Project expenses 22

8 Conclusion 23

9 Reference 24
 LIST OF FIGURES

Figure Name Of Figure Page

No. No.
2.1 Portable Dust Extractor 7
5.1 Actual final project CAD model 15
5.2 Rough design 15
5.3 Electric motor 16
5.4 Cyclone separator 17
5.5 Actual cyclone separator 17
5.6 dustbin 18
5.7 Wheels 18
5.8 Hose pipe 19
5.9 Angles 19
7.1 Final prototype 23

TABLE NAME OF THE TABLE PAGE NO.

NO.

1 Specifications of motor 15
 1. ABSTRACT
A dust collector is a system used to enhance the quality of air released from industrial
and commercial processes by collecting dust and other impurities from air or gas. Designed
to handle high-volume dust loads, a dust collector system consists of a blower, dust filter, a
filter-cleaning system, and a dust receptacle or dust removal system. It is distinguished
from air purifiers which use disposable filters to remove dust.

Dust collectors are used in many processes to either recover valuable granular solid or
powder from process streams, or to remove granular solid pollutants from exhaust gases prior
to venting to the atmosphere. Dust collection is an online process for collecting any process-
generated dust from the source point on a continuous basis. Dust collectors may be of single
unit construction, or a collection of devices used to separate particulate matter from the
process air. They are often used as an air pollution control device to maintain or improve air
quality.

This project focuses on design and development of a machine which will collect
whatever the dust is generated by various machining processes and analysis and calculations
required for the Designing the Machine.

\
 2. INTRODUCTION

A dust collector is a system used to enhance the quality of air released

from industrial and commercial processes by collecting dust and other impurities from
mechanical equipment’s. Dust collector are used in many processes to either recover
valuable granular solid or powder from industrial processes. Bulk material consists of
relatively large and heavy particles, with no fine dust, it may be possible to collect the
material in a dust bin, where the solid material falls under gravity to the bottom of the
bin while the gas is taken off through a suitable vent. Many construction details such
as inlet location, hopper design, bin design, casing, blower, impeller and motor. It is
widely involved in many industrial processes such as welding, rubber, and plastic, etc.
In view of above, information about working of bag type filters, materials, and
different types of bag type design considerations, maintenance and useful terms
related with filters is given. Gas-solid separation devices associated with pneumatic
conveying systems have two functions.

Figure No. 2.1 Portable Dust Extractor

To recover the conveyed material as much as possible and to minimize pollution of

the environment by the working material. Different separation mechanisms used based on the
size of particles are: gravity settling chambers, cyclone separators and bag type fabric filters.
If a bulk material consists of relatively large and heavy particles, with no fine dust, it may be
possible to collect the material in a simple bin, where the solid material falls under gravity to
the bottom of the bin while the gas is taken off through a suitable vent. However, if a bulk
material is of slightly smaller particle size, it may be required to enhance the gravitational
effect. The most common method for this is to impart spin to the gas-solid stream so that the
solid particles are thrown outwards while the gas is drawn off from the centre of the vortex. A
cyclone separator works on this principle.

If particles are fine and especially if they are also of low density, separation in a
cyclone may not be fully effective, and in this case the gas-solid stream may be vented
through a fabric filter. For materials containing extremely fine particles or dust, further
refinement in the filtration technique may be necessary, for example, use of wet washers or
scrubbers and electrostatic precipitators. In general, the finer the particles that have to be
collected, the higher will be the cost of a suitable separation system. Airborne dusts which
may be encountered in industrial situations are generally less than about 10µm in size.
Particles of this size can be taken into the body by ingestion, skin absorption or inhalation.
The former is rarely a serious problem and, although diseases of the skin are not an
infrequent occurrence, it is inhalation that presents the greatest hazard for workers in a dusty
environment

2.1 The most common types of centrifugal, or inertial, collectors in use today are:

1. Single-cyclone separators:

Single-cyclone separators create a dual vortex to separate coarse from fine dust. The
main vortex spirals downward and carries most of the coarser dust particles. The inner
vortex, created near the bottom of the cyclone, spirals upward and carries finer dust particles.

2. Multiple-cyclone separators:

Multiple-cyclone separators consist of a number of small-diameter cyclones,

operating in parallel and having a common gas inlet and outlet, as shown in the figure, and
operate on the same principle as single cyclone separators—creating an outer downward
vortex and an ascending inner vortex.
 Multiple-cyclone separators remove more dust than single cyclone separators because
the individual cyclones have a greater length and smaller diameter. The longer length
provides longer residence time while the smaller diameter creates greater centrifugal force.
These two factors result in better separation of dust particulates. The pressure drop of
multiple-cyclone separators collectors is higher than that of single-cyclone separators,
requiring more energy to clean the same amount of air. A single-chamber cyclone separator
of the same volume is more economical, but doesn't remove as much dust.

3. Secondary-air-flow separators:

This type of cyclone uses a secondary air flow, injected into the cyclone to
accomplish several things. The secondary air flow increases the speed of the cyclonic action
making the separator more efficient; it intercepts the particulate before it reaches the interior
walls of the unit; and it forces the separated particulate toward the collection area. The
secondary air flow protects the separator from particulate abrasion and allows the separator to
be installed horizontally because gravity is not depended upon to move the separated
particulate downward.

2.2PROBLEM STATEMENT :

During Machining process fine composite particles of the work piece is suspended in
the atmosphere and then settle down on the floor and on the machines and work area . This
causes dust collection problem and create dusty environment. It increases the time and efforts
for collection of dust .

2.3 OBJECTIVE

There can be several objectives of collecting dust, some of the important reasons can
be following.

 Protection of the operator.

 Protection of the production equipment from the dust.
 Protection of the job from the effect of dust.
 Protection of quality of environment in a premises.
 Recovery of the expensive materials.
2.4 METHDOLOGY:

1. To study the requirements of company.

2. To study the waste material to be collected.
3. To decide best working model for the removed composite material.
4. To decide various components of machine that will give desired output.
5. To calculate the dust collection capacity.
6. To decide the dimensions of components of dust extraction system.

7. To start actual making of machine.

2.5 FUTURE SCOPE

Apr 05, 2019 (Herald keeper via COMTEX) -- The qualitative research study conducted by
Market Study Report on Global Dust Collector Market Report provides primary Data,
surveys, Scope of the Product and vendor briefings. The market dynamic forces have been
determined after conducting a detailed study of the Global Dust Collector market.

A dust collector is a system used to enhance the quality of air released from industrial and
commercial processes by collecting dust and other impurities from air or gas. Designed to
handle high-volume dust loads, a dust collector system consists of a blower, dust filter, a
filter-cleaning system, and a dust receptacle or dust removal system. It is distinguished from
air cleaners, which use disposable filters to remove dust.

Global dust collector industry is not very concentrated, as the manufacturing technology is
getting mature and mature. Many manufacturers compete in the market; the leading
manufactures are Alstom, Long king, and Feida. The top 4 manufacturers occupied about
20% of the total revenue market in 2016.

China remains the largest market of dust collector with a market sales share of about 40% in
2016, followed by Europe and North America, with market share of 16.45% and 14.70%.
Despite the presence of competition problems, due to the global recovery trend is clear,
investors are still optimistic about this area; the future will still have more new investment
enter the field.
 3. LITERATIRE SURVEY

1. Mohapatra, Mishra and Choudhary et. al. was studied on teek wood dust (TWD)
reinforced epoxy composite and thermal conductivity is analyzed. He used hand lay-up
method for fabrication of composite with dust particle size 150, 200, 250-micronsand having
volume fraction 6.5, 11.3, 26.8, 35.9. It was observed after experiment,thermal conductivity
of composite decreases with respect of increase in filler content. Experimental results
(TWD,150μ) was also compared with the theoretical models (such as Rule ofMixture model,
Russel model, Maxwell model Baschirow & Selenew model) and found that the errors
associated of all models in respect of experimental ones lie with range of 20.14 to 84%, 74
to111.84%, 79.13 to 115.79% and60.13 to 102% respectively. The newlydeveloped
composite materials can be used for applicationsin automobile interior parts, electronic
packages, ceiling roofs, building constructions, sports goods and furniture etc.

2. Jayaramudu, Agwuncha, Ray, Sadiku, and Rajulu et. al. studied with natural
Polyalthiacerasoide woven fabrics mixing with epoxy composite. The woven fabrics
extracted from bark of the tree to make hybrid composites. The hand lay-up technique was
used to fabrication of hybrid composite at room temperature. The surface modification of
woven fibre was done by the process of alkali treatment. The microstructure and morphology
studied was completed using Fourier transforms infrared spectroscopic (FTIR) and scanning
electron microscopic methods respectively. The FTIR analyses represent the least value of
hemi-cellulose and lignin contents of alkali treated woven fabric. The hybrid composite
suggested for various applications in building and construction industries as panels for
partitioning, flooring, storage tanks and table taps, etc.

3. Barnasree, Kumar, and Bhowmik et. al. were studied wood dust particle reinforced in
epoxy based composite for analysis of mechanical behavior. The sundy wood dust particle
used as reinforcement and LY 556 epoxy for resin. The six different percentage of filler
particle used in study. Tensile and flexural test were carried out using UTM and sample size
based on ASTM Standard. The different design parameters like as filler content and speed for
loading with tensile and flexural strength using GRA were optimized.Optimizationby GRA
has the advantage of selecting best and worst options. GRG shows that test run number 13 is
the best suited and test run number 3 is the least important. Epoxy composite with 10
fillercontents (wt%) at corresponding speed of 1 mm/min shows best performance and on the
other hand with 0 filler content (wt%) at the speed of 3 mm/min shows theworst performance.

4.Time-of-Flight Collection Models. Leith and Licht (1972) assumed turbulence causes a
uniform particle concentration, then calculated the radial distance a particle must travel to
touch the wall. They were able to estimate collection efficiency for various cyclone designs
with considerable accuracy. Clift et al. (1991) improved the Leith and Licht model prediction
by changing the equation and the residence time assumption it depended on. Dietz (1981)
divided the cyclone into sections and included terms for particle transport between them.
Mothes and Löffler (1988) improved on the Dietz model by adding diffusion (turbulent
dispersion) and re-entrainment. Particle re-entrainment and turbulent diffusion were also
included in the model by Li and Wang (1989). Another improvement was to not assume
uniformity, but include a term for the radial particle concentration gradient (Zhao, 2005). Both
the balanced-forces and time-of-flight categories, and later models that combine these
principles, are equally elegant in their simplicity and predictive over their specified range.
Yet no model can predict the influence of an excluded parameter. If, for instance, the model
does not include a term for particulate loading, its influence will be ignored.

5.Dinesh and Jagdish et. al. research focused on wear study of sisal fibre reinforced epoxy
based composite materials. LY-556 and HY 951 used as resin and hardener respectively. 10%,
20%, and 30% sisal fibre used as reinforcement during fabrication of composite by had lay-up
method. By increasing the percentage of the sisal fibre in fabrication work enhance the weight
loss of the specimen of wear test. SFRECM can be used as substitute materials for human
Orthopedic Implants.

6.Motaung and Anandjiwala et. al. studied of behavior of sugar cane bagasse particle
reinforced composite like as, thermal degradation and kinetics of the untreated, alkali treated
and sulphuric acid treated sugar cane bagasse (SB). It had been estimated by non-isothermal
thermogravimetric investigation under nitrogen atmosphere The alkali treated fabricated
samples represent the maximum values of thermal degradation. FTIR and XRD established
different functionalization with fibre surface and improved crystallinity. The NaOH treated
sample exposed the maximum thermal stability with acid treated samples presented the
lowest.
7.Ramachandran et al. (1991) found published data for 98 cyclone designs and used
statistical methods to derive a model for presure drop based solely on cyclone dimensions
(cylinder diameter, inlet height and width, exit tube diameter, exit tube protrusion, cylinder
height, total height and bottom diameter). The statistical model predicted pressure drop better
than the empirical models of the 1940s and 1950s. Elsayed and Lacor (2010) used response
surface methodology to find optimal values for each of seven geometric dimensions of a
cyclone design, using the Muschelknautz and Kambrock (1970) equations to estimate pressure
drop and cutpoint. They claimed to have found a design having a collection efficiency equal to
the Stairmand cyclone, but with half the pressure drop. Salcedo and Cândido (2001) used
similar numerical optimization (a stochastic adaptive random search to solve a profit function)
to explore novel geometries, developing a proprietary design claimed to have only 53% the
emissions for the same pressure drop of a Stairmand (1951) cyclone. Response surface
methodology was used elsewhere to find the natural vortex length (Qian and Zhang, 2005).
Some weaknesses with these approaches are: their dependence upon extrapolations of semi-
emperical models of limited accuracy even over the range of their derivation; their use of
diverse data sets that may have inconsistent controls and interpretations; and the fact that a
statistical model, like any other model, cannot account for parameters that are not included.
 4. PROJECT PLAN

Month-wise plan:

Sr.no. Month Work

1 August Group Formation

2 September Problem Statement was Identified

3 October & Study on given problem and finding solution

November
4 November Related Literature survey and gathered
information

5 November Review 1 conducted

6 December, January Dimension consideration of existing

model and further calculations for new
system, Objectives for proposed system.
Review 2 conducted
7 February System Layout Objectives for proposed
system & Review 3 conducted

8 March & April 3-D model Drawing in Catia, Review Stage 1 and
exam
9 June No physical manufacturing work due to
lockdown & Final Project Review
4. FINAL DESIGN AND MAIN COMPONENT OF THE MACHINE

Figure 5.1 Actual final project CAD model

Figure 5.2 Rough design

4.1 Electric Motor:
The electric motor is a machine capable of converting electrical energy into
mechanical energy. The induction motor is the most widely used type of motor,
because it combines all the advantages offered by the electrical energy such as low
cost, easy of supply and distribution, clean handling and simple controls - together
with those of simple construction and its great versatility to be adapted to wide ranges
of loads and improved efficiencies.

Figure 5.1.1 Electric motor

4.2 Specification of motor:

Horse Power 1 HP Motor 2 HP Motor

voltage 115V 115V
Air flow 660CFM 1189CFM
RPM 3400RPM 3450RPM
Material Steel Steel
4.3 Cyclone Separator:

Cyclone separators or simply cyclones are separation devices (dry scrubbers) that use
the principle of inertia to remove percolate matter from flue gases. Cyclone separators
is one of many air pollution control devices known as proclaimers since they
generally remove larger pieces of particulate matter.

Figure5.3.1 Cyclone Separator

Figure 5.3.2 Actual cyclone separator

4.4 Dustbin:

Figure 5.4.1 Dustbin

4.5 Wheels:

Figure 5.5.1 Wheels

4.6 Hose pipe:

A hose is a flexible hollow tube designed to carry fluids from one location to another.
Hoses are also sometimes called pipes (the word pipe usually refers to a rigid tube,
whereas a hose is usually a flexible one), or more generally tubing. The shape of a
hose is usually cylindrical (having a circular cross section).

Figure 5.6.1 Hose pipe

4.7 Angles:

Figure 5.7.1 Angle

5. CALCULATIONS

6.1Design of impeller:
Impeller eye and inlet duct size Let inlet duct size be 10% higher than impeller
eye size or impeller inlet diameter. This will make conical insertion of inlet duct
and flow acceleration at impeller eye or inlet.
Dduct=1.1 Deye

Assuming no loss during 90º turning from eye inlet to impeller inlet, the eye inlet
velocity vector will remain same as absolute velocity vector at the entry of impeller.

i.e. Veye =V1=Vinl

Further let tangential velocity component be 10% higher than axial velocity
component for better induction of flow.
So, Inlet Tip velocity
U1=1.1 V1=1.1 Vml
π
Discharge, Q= *Deye*Deye *V1
4
4Q
V1= π∗D 1∗D 1
¿
¿
U1=1.1V1

Here Q=0.5 m3 /s and speed of impeller rotation N=2800 rpm,

Impeller Inlet Diameter
D1=0.150 m = Deye
Peripheral speed at inlet

U1=1.1V1
=10.84 m/s
V1=22.45 m/s =Vm1= Veye
Impeller inlet blade angle (Refer Figure 3.5 for inlet velocity triangle)

Dduct=1.1 D1= Vm1=Veye

W1= √ u 12+ v 12 =33.37m/s

v 1 22.45
tan β = = =42.35 degree
u 1 24.63
Here Z=16 and assumed blade thickness t = 2 mm
Q = [πD1-zt]*b1*vml
b1 = 0.045 m = 45 mm
Impeller outlet parameters
The Fan Power =∆P * Q = 981.2 * 0.5 = 490.6 W
Considering 10% extra to accommodate flow recirculation and impeller exit
hydraulic losses.
So 1.1 the fan power = 1.1 490.6 = 53.66 W
Power, P = m *Ws
Specific work done,
==

Euler power = mVu2 *U2

Taking = 0.8U8 (Assuming slip factor = 0.8 for radial
blades)

539.66 = 1.165 0.5 0.8

U2 = 34.03 m /s
Vu2 = 0.8 * 34.03 – 27.22 m/s

And
D2 = 0.232 m

Taking width of blade at inlet = outlet blade width

b1=b2

Q=[πD2-zt]*b1 *vM2

0.5=[(π*0.232)-(16*2*0.0001)]*0.045* Vm2

Vm2=16 m/s

Wu2=0.2u2=6.81m/s

W2= √ Wu 22 +vm 22=17.39 m /s

V2=√ Vu22 + vm22=31.58 m/s

Vm 2 16
tanα= = =0.59
Vu 2 27.22

α2=30.45 degree
 8.CONCLUSION
The glass fibre dust collector machine we designed and fabricated was able to
produce the required output by the industry where it is intended to be used.
Also, this machine can also be used in other industries where similar type of problem
occur.
Our goal was to build a machine that can collect maximum fine particles (dust) of
Glass fibre and maintain clean environment.
Also we used innovative idea of using cyclone dust separator. The material costs of
building the machine was managed to be kept to a minimum, though at a cost of
greatly increased building time.
Our machine will surely benefit the environment as it reduces the harmful glass fibre
dust and other similar waste released in the environment and helps to recycle them.
The project has taught us a lot as well as tested our abilities while still fulfilling the
requirements set on it at the outset. We were exposed to the knowledge of CAD
modelling, fabrication, welding, grinding, and many more.
 9. REFRENCES

[1] G. C. Frazier, C. Mason, E. J. Badin, Thermogravimetry combustion characteristics of

high carbon fluidized-bed cyclone ashes, Fuel. 63 (1984) 499–504.

[2] Y. B. He, J. S. Laskowski, Effect of dense medium properties on the separation

performance of a dense medium cyclone, Minerals Engineering. 7 (1994) 209–221.

[3] J. Yang, G. Sun, C. Gao, Effect of the inlet dimensions on the maximum-efficiency
cyclone height, Separation and Purification Technology. 105 (2013) 15–23.

[4] A. Surmen, A. Avci, M. I. Karamangil, Prediction of the maximum-efficiency cyclone

length for a cyclone with a tangential entry, Powder Technology. 207 (2011) 1–8.

[5] C. Hui, S. Guogang, Effects of wall roughness on the flow field and vortex length of
cyclone, Procedia Engineering. 102 (2015) 1316–1325.

[6] S. Morsi, A. Alexander, An Investigation of Particle Trajectories in Two-Phase Flow

Systems, J. Fluid Mech. 55 (1972) 193–208.

[7] Karataş MA, Gökkaya H (2018) A review on machinability of carbon fiber reinforced
polymer (CFRP) and glass fiber reinforced polymer (GFRP) composite materials. Defence
Technology.

[8] Sheikh-Ahmad JY (2009) Machining of polymer composites. Springer, New York,

London.