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Design of Hammer Mill for Crushing of Glass Waste

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 International Journal of Research in Advanced Engineering Technologies

Vol.1 Issue1 July-August 2017

www.ijraet.org

Design of Hammer Mill for Crushing of Glass Waste

Ejiroghene Kelly Orhorhoro1,Oghenekevwe Oghoghorie2
1
Facultyof Engineering, Delta State Polytechnic, Otefe-Oghara,
Nigeria.
2
Faculty of Engineering, University of Benin, Nigeria

Abstract
Solid waste management is major problem in developing countries. Solid waste includes organic waste
(food waste) and inorganic waste (glass waste, plastic waste, etc.). Unlike the inorganic waste, the
organic waste is biodegradable and easy decompose. This research work focus on the design of a hammer
mill for crushing of glass waste into some useful end products. The machine consists of hopper feed tray,
crushing chamber, right and left side fixed plate, rotating blades, crush product outlet tray, machine main
frame, V-belt and electric motor. The machine was designed such that a minimum crushing force of
215.6N and crushing power of 5hp can uniformly crush the glass waste into a semi-finish end product
which can serve for other purpose. The results of the physical model showed that when the machine is
fabricated, it can be used domestically and commercially for glass waste management.

Keywords: Solid waste management, glass waste, hammer mill, power, crushing force.

1. Introduction
Solid waste managementin developing countriesis a major concern to government and the society.
Increase in industrialization and human population has brings about an increase in the quantity of waste
generated on daily basis [1]. Solid waste are the useless and unwanted products in solid state, discarded
by members of the society [2, 3].The poor management of glass waste in developing country is a source
of concern to the society. This waste poses a threat to urban management, defaces the aesthetics of the
country’s citiesthrough mounting heaps of glass waste, and also a health hazard to citizens through
theblockage of drainage systems, causing erosion and flooding [1]. The standard of waste management in
developing countries is at its lowest with poor documentation of waste generation rates, inefficient
storage and collection system, and the under-utilization of disposal sites [4]. Waste management is every
activity and action carried out to manage waste from the time it is generated to its final disposal. This
includes amongst other things, collection, transport, treatment and disposal of waste together with
monitoring and regulation [5].Waste management deals with all kinds of waste, whether generated during
the extraction of raw materials, processing of raw materials into intermediate and final products,
consumption of final products, or other human activities including municipal (residential, institutional,
commercial), agricultural, and special (health care, household hazardous wastes, sewage sludge).

Waste management practices are not uniform among countries/continents (developed and developing
countries), regions (urban and rural area), and sectors (residential and industrial) [6]. Throughout history,
waste has been generated by humans, in areas with low population density, waste generation may have
been negligible but in areas with considerable number of person’s waste cannot be neglected or over
look. This has led to the formulation of various waste management policies and technology such as

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anaerobic digestion (biodegradable waste), crushing machine (plastic and glass waste), incinerator
(paper, textile,

plastic, etc.), landfill, gasification, etc. [1,7,8]. Solid waste can be classified on the basis of their source
as: Municipal Solid Waste,Industrial Solid Waste and Agricultural Solid Waste. Most cities in
developing countries spend 20-50% of theirenvironmental budget on solid waste management and only
20-80% of the waste is collected. The standard of waste management in developing countries is at its
lowest with poordocumentation of waste generation rates, inefficient storage and collection system, and
theunder-utilization of disposal sites [4].
There are various kinds of solid wastes and they can be classified into organicwaste (food waste) and
inorganic (glass waste, plastic waste, etc.). Most waste gotten from the home are usually biodegradable
and do not pose so much problems in land fill. Non-biodegradable solid waste (glass waste) usually cause
a major problem in landfill and also in the sea as they do not go back to their original state so easily [9].
Glass waste is of very great importance as it does not ever degrade and it is 100% recyclable. Recycling
is an excellent way of saving energy and protecting the environment. Waste glass comes from various
sources, in the form of glass sheets, containers, jars and bottles, and can be recycled with the help of a
crushing machine to avoid generating new glass, which in turn saves energy. Glass crushing machines
are designed with the aim of pulverizing glass to aid in the recycling process, and can be used
independently by institution, bar, hotel and restaurant owners alike, or as a part of an integrated glass
recycling system, comprising of crushers and material separation machines.

Many institution, homes and bars make use of bottles for drinks; processed food, water, etc. which are
preserved in it. After consumption of such goods/products, the bottle waste on regular bases which
usually end up in landfills, rivers, dumpsites, etc. and this causes a lot of nuisance, block drainage
system, flooding, and pollution as they do not decompose over time. These glass bottles can be recycled
to produce new bottles, used to reinforce blocks and as sand fills in swampy areas. The energy needed to
create new bottles can be cut by almost half when the older ones are recycled and used. Hence in other to
manage the effect of waste on the environment and save energy and cost, there is the need for a glass
recycling via glass crushing machine. The aim of this research work is to design a glass crushing machine
for recycling of glass waste.

2. Materials and Methods

The machine consists of hopper feeding tray, a crushing chamber, right and left side fixed blade, rotating
blades, ball bearings, bolts and nuts, crushed product outlet tray, electric motor, machine main frame and
V-belt. The machine is design to provide resistances against:
 Friction/ impact on rubbing surface
 Strain of the machine element and possible heating up cause by operation of the machine.
The machine is designed such that he efficiency of the hammer mill can be increased via the following means:
 Increase in resistance against wear: This can be achieved by reducing the strain in the material of its
working tool.
 Decreasing the number of deformation cycles of the materials to ground and
 Finally, by decreasing the breaking stress of the working tool of the materials.

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Design consideration
 The hammer mill machine will consist of hopper feed tray connected to the crushing chamber
 The hammer mill is expected to operate within a rotating speed of 1440rpm

 It must not deliver a crushing force greater than 300N

 The crushing power must not exceed 8hp
 Determination of approximate length of the belt (m)
 Estimation of required toque (Nm)
 Estimation of belt tension

Design specifications
The design factorsconsidered were safety, functionality, cost, manufacturability and assembly, and
maintenance. Table 1 highlights the design specifications used.

Table 1. Design specifications

S/N Design Basis Material/Rating Justification

Specification
1 Power Determines the energyconsumption Low speed motor The operational system of
consumption of themachine and itmanufacturing the machine requires low
cost. speed motor.
2 Pulley Ratio of input to output speed from Cast Iron Reduction of electric
electric motor to shaft. motor speed.
3 V-Belt Power transmission Fiberreinforced Low speed and high
rubber torqueoperation.
4 Shaft High strength, wearresistant, Machin Stainless steel Corrosion resistance,
able and transmission of torque. betterabsorb shear force
andcompressive force.
5 Machine main Provides rigidity for themachine and Mild Steel Angle ASTM specification.
frame preventsfailure caused by fatigue. bar
6 Rotating blades To properly crushed waste glass Tungsten steel Hard, tough and good
tensile strength
6 Design life Life span of the machine - Compensation for total
costof the machine and
qualityof materials used.
7 Machinecost An overview of thefabrication cost. Affordable Domestic and Industrial
use

Detail design
Determine of crushing force and crushing power [10]
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P = FV (1)
Where,
P = Crushing power
𝜋𝐷𝑁
V = speed= 60
(2)
Equation (1) becomes;
𝐹𝜋𝐷𝑁
𝑃= (3)
60

𝐹 = 𝑚𝑔 = 22 × 9.8 = 215.6𝑁
Power to crush the glass waste is the power required to drive the shaft.
Therefore,
215.6 × 𝜋 × 0.15 × 1440
𝑃= = 2438.69𝑤𝑎𝑡𝑡𝑠
60
But,
1hp = 750 (Approximate value)
Thus,
2438.69watts = 3.25hp
If a safety factor of 1.5 is considered,
Required power for crushing of glass waste = 5hp (Approximate value)
This implies, that for proper crushing of glass waster, the machine will require a power of 5hp.

Determination of belt length

The belt length can be obtained as follow [10]:
𝜋 𝐷1 +𝐷2
𝐿 = 2𝐶 + 2
𝐷1 + 𝐷2 + 4𝐶
(4)

𝜋 0.15+0.05
= 2 × 0.40 + 2 0.05 + 0.15 + 4×0.40
= 1.24𝑚

Distance between driver and driven pulley

The center tocenter distance between driver and driven pulley is given as:
𝐶 = 2𝐷1 + 𝐷2 (5)
Where;
D1 = Diameter of the driver =50mm = 0.05m
D2 = Diameter of the driven = 150mm = 0.15m
C= Centre to center distance between driver pulley and driven pulley
Therefore;
𝐶 = 2 × 150 + 50 = 400𝑚𝑚 = 0.40𝑚

Design for speed ratio for belt drive

Velocity ratio for belt drive is the ratio between the velocity of the driver and the
follower (driven). It may be expressed mathematically as:
𝑁2 𝐷
𝑁1
= 𝐷1 (6)
2

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Where;
D1 = diameter of the driver = 50mm= 0.05m
D2 = diameter of the driven = 150mm = 0.15m
N1 = speed of the driver = 1440rpm
N2 = speed of the driven =?
Therefore;
1440 × 50
𝑁2 = = 480𝑟𝑝𝑚
150
N1 : N2 = 1: 3

Determination of lap angle

The equation is expressed as follow [10]:

𝐷2 − 𝐷1
𝛼 = 180 ± 2 sin−1
2𝐶
Where;
α1 = Angle of lap for driving pulley (rad)
α2 = Angle of lap for driven pulley
C = Centre to center distance between driving pulley and driven pulley
However, for open belt, angle of lap is given as
𝐷2 −𝐷1
𝛼 = 180 − 2 sin−1 2𝐶
(7)
Therefore;
0.15−0.05
𝛼 = 180 − 2 sin−1 2×0.40
= 165.60
Converting the angle from degree to radian;
𝜋
165.6° × = 2.89rad
180°

Determination of torque
The torque is obtained from the equation as follow:
𝑇 = 𝐹𝑙 (8)
Where;
T = Torque
F = Force
L = Length of crushing blade
Therefore;
𝑇 = 215.6 × 0.402 = 88.67𝑁𝑚

Belt tension
The belt tension can be calculated as follow [10]:
T1
2.3log T2
= μα (9)
Where,
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𝛼 = angle of wrap of an open belt

μ= coefficient of friction = 0.47 [10]
T1= Tension in the tight side of the belt
T2= tension in the slack side of the belt
Also;
P = T1 − T2 V (10)
Where,
P = Belt power (watts)
V = Belt speed (m/sec)
T1 and T2 are tension on the tight and slack sides respectively (N)
Therefore;
T1
2.3log T2
= 0.47 × 2.89

T1
2.3log[ ]= 1.358
T2

T1 1.358
Log[T2]= 2.3
T1
Log T2
= 0.5905
𝑇1
= 𝑒 0.5905
𝑇2
𝑇1
𝑇2
=1.8049
Therefore,
T1= 1.8049T2 (11)
But,
P = T1 − T2 V
Thus,
60P 60 × 2438.69
T1 − T2 = = = 646.80N
πDN π × 0.05 × 1440
T1 = 646.80N T2 (12)
Equating equation 11 and equation 12
1.8049 T2= 646.80N T2
1.8049 T2- T2= 646.80N
Therefore,
T2= 803.58N
Therefore,
T1 = 646.80N + 803.58N = 1450.38N
Figure 1 shows isometric skeletal view of Hammer mill and Figure 2 model view of Hammer mill

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Fig. 1 Isometric skeletal view of Hammer mill

Fig. 2 Model view of Hammer mill

3. Results and Discussion

Figure 2 shows the physical model view of the design hammer mill for crushing of glass waste. The
machine was designed based on various design consideration and specification listed above. From
mathematical modelling and design calculation, the following values were obtained; a crushing force and
crushing power of 215.6N and 5hp respectively. This simply showed the machine will use minimum
crushing force in comparison to 300N crushing force in design consideration and 5hp against 8hp in
design consideration. A safety factor of 1.5 was used and this means that the actual poor required was
3.33hp which is minimum enough in terms of cost consideration and functionality. Also, a belt length of
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1.24m was obtained. The distance between driver and driven pulley was calculated as 0.4m and this gives
a speed ratio of 1:3 (i.e. N1: N2 =1:3). The calculated value of crushing force was used to determine the
torque required which was obtained as 88.67Nm. The analysis of the physical modeling using
SolidWorks showed that the machine will be able to crush glass waste material if fabricated for domestic
and commercial use in developing countries.

Conclusion
This research work focus on design of cost effective and affordable glass waste recycling machine in
developing countries which can be used in crushing of glass waste into some useful products. The
machine was successfully designed. The design calculation showed that the machine required minimum
crushing force and crushing power for it operation. A physical model of the machine was analyze using
SolidWorks and the outcome prove that the machine is efficient and when fabricated for use, it should be
able to crush glass waste successfully into some useful end products.

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