polyethylene pipes systems -...
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PEPSPEPS
Polyethylene Pipes Systems
Prototype ReviewApril 15, 2010
Lina GarciaKathy BuiIan MattsWilliam Kyei-Manu
PEPSPEPS
Polyethylene Pipes Systems
Prototype ReviewApril 15, 2010
Agenda1. Purpose and Goal
2. Prototype Design
3. Sample Production
4. Issues and Future Improvements
5. Sample Testing
6. Cost analysis-Cost of device manufacturing-Cost of operation
7. Gantt Chart
Agenda
4. Issues and Future Improvements
Cost of device manufacturing
Purpose and Goals• Develop a low-cost and low
produce drip irrigation pipes by recycling High Density Polyethylene (HDPE) shopping bags
• Maximize pipe-strength to cost ratio
Criteria of Success:
• A functional and scalable process and prototype of irrigation tubes• Tube diameter = 0.75’’• Water pressure = 0.15 atm1
Purpose and Goalslow-tech method to
produce drip irrigation pipes by recycling High Density Polyethylene (HDPE) shopping bags
strength to cost ratio
A functional and scalable process and prototype of
1 Krishak Bandhu Family Nutrition Kit
Initial Prototype DesignInitial Prototype Design
Heat TransferHeat Transfer
Prototype Number 1
Insulated heating element
Adjustable collars allow
for roller alignment
Prototype Number 1
Insulated heating element Heated Roller
Free RollerFree Roller
Allow for lateral
adjustments
Sample Production
• Temperature varies based on voltage input• Pressure is unquantified/unknown at the moment
Voltage: 40V Temp Range: 118+Temp Range: 118+
Sample Production
Temperature varies based on voltage inputPressure is unquantified/unknown at the moment
Issues and Improvements
Poor temperature control
Unknown pressure
Free roller doesn’t always spin
Welding up to 6 layers of bags only
Issues and Improvements
Add temperature control
Attach pressure gauge or eliminate pressure variablepressure variable
Add gears
Heat the second roller
Strength Model: Non
What we expected in theory:
Source: O.A.
Heat Weld Strength Predictions Using a Thermal and Polymer Chain Diffusion Analysis
Strength Model: Non-Fickean Diffusion
What we expected in theory:
σw = strength of weldσm = strength of raw materialtm = time spent above melting Ttrep = reptation timev = velocityT = processing temperatureD = diffusion
Source: O.A. Ezekoye, C.D. Lowman, M.T. Fahey and A.G. Hulme-Lowe.
Heat Weld Strength Predictions Using a Thermal and Polymer Chain Diffusion Analysis
Image Source: http://nobelprize.org
Peel Test
ASTM D6392-08:"Standard Test Method for Determining the Integrity of Nonreinforced Geomembrane Seams Produced Using Thermo-Fusion Methods”*Methods”*
*with some modifications (sample length, and extension rate)
Peel Test
"Standard Test Method for Determining the Integrity of Nonreinforced Geomembrane Seams
Fusion
*with some modifications (sample length,
Peel Test ResultsPeel Test Results
Next Steps in Sample Testing
• Strength shows some dependence on temperature
• Crystallinity doesn’t show any dependence on temperature
• Imagingo Weld surface (SEM, Light Transmission
Microscope)o Weld cross-section (Stereomicroscopy)
Next Steps in Sample Testing
Strength shows some dependence on temperature
Crystallinity doesn’t show any dependence on
Weld surface (SEM, Light Transmission
section (Stereomicroscopy)
Cost of Device Production
Aluminum rollersHeating elementInsulationMachining8020 Aluminum Extrusion 8020 Aluminum Extrusion Steel rods Overhead Cost (nuts/bolts,shipping, etc)
Total Cost of Device* ~ $290-$300
*Final prototype may cost more/less depending on improvements and replacement of parts
Cost of Device Production
Overhead Cost (nuts/bolts,shipping, etc)
$300
*Final prototype may cost more/less depending on improvements and replacement of parts
Cost of Production
Considering:Annual Labour Cost (based on minimum wage)Annual Energy Cost (based on price/kWh)
Total Cost Per Kit* ~ $1.60Total Cost Per Kit* ~ $1.60
*Each kit includes 20 meters of tubing based on the Krishak Bandhu Family Nutrition Kit ($6.00)
Cost of Production
Cost (based on minimum wage)Annual Energy Cost (based on price/kWh)
*Each kit includes 20 meters of tubing based on the Family Nutrition Kit ($6.00)
Gantt ChartGantt Chart
Gantt ChartGantt Chart
QUESTIONS?QUESTIONS?QUESTIONS?QUESTIONS?
Peel TestASTM D6392-08: "Standard Test Method for Determining the Integrity of Nonreinforced Geomembrane Seams Produced Using Thermo
Geomembranes are composed of Polyethylene of various densities, Polyvinyl Chloride, or Polypropylene.
Variable ASTM
Sample Width 25 mm
Sample Height 150 mm
Extension Rate 50 mm/min
Grip 25 mm x 25 mm
Peel Test08: "Standard Test Method for Determining the Integrity of
Nonreinforced Geomembrane Seams Produced Using Thermo-Fusion Methods”
Geomembranes are composed of Polyethylene of various densities, Polyvinyl Chloride, or Polypropylene.
ASTM Actual
25 mm
10 mm
50 mm/min 5 mm/min
25 mm x 25 20 mm x 25mm
Sample Peel Test Results
8
10
12
14
Load (N)
-2
0
2
4
6
8
-4 -3 -2 -1 0 1 2 3 4 5 6 7
Load (N)
Extension (mm)
Sample Peel Test Results
8 9 10 11 12 13 14 15 16 17 18 19 20 21
Extension (mm)
Tube Strength
•
•Source: Pipeline Engineering Design
Tube Strength
•Maximum Weld Strength:
•Maximum Pressure:
X-Ray Diffraction Test ParametersNo ASTM Standards found for measuring polymer crystallinity using XRD
Equipment:PANalytical Multipurpose Diffractometer in 13
Parameters:•5°to 70°•90 min/sample•At 40mA•Max penetration depth exceeded thickness of entire sample
Ray Diffraction Test ParametersNo ASTM Standards found for measuring polymer
PANalytical Multipurpose Diffractometer in 13-4027
Max penetration depth exceeded thickness of entire
X-Ray Diffraction DataRay Diffraction Data
Strength and Crystallinity Results
Sample Side Maximum Load
Pressure
Control
1 High1 High
2 High
4 High
5 High
6 High
7 Low
7 High
8 High
9 Low
9 High
Strength and Crystallinity Results
Maximum Load Crystallinity
N %
23 72.45
5.8 67.15.8 67.1
68.62
3.9 64.56
7.5 63.1
18.5 66.64
70.56
12 63.01
66.25
12.25
15.25
68
70
72
74
% Crystallinity
% Crystallinity vs. Maximum Load
High Pressure
62
64
66
0 5 10
% Crystallinity
Maximum Load (N)
% Crystallinity vs. Maximum Load
Raw Bags
15 20 25
Maximum Load (N)
Cost of Device Production
Aluminum rollers~$80Heating element ~ $70Insulation ~ $10Machining(5hours X $10/hour) ~ $50Machining(5hours X $10/hour) ~ $508020 Aluminum Extrusion ~$20Steel rods ~ $40 Overhead Cost (nuts/bolts,shipping, etc) ~ $20
Total Cost of Device ~ $290
Cost of Device Production
Machining(5hours X $10/hour) ~ $50Machining(5hours X $10/hour) ~ $508020 Aluminum Extrusion ~$20
Overhead Cost (nuts/bolts,shipping, etc) ~ $20
Total Cost of Device ~ $290
Cost of Operation and Production
Annual Labour Cost:($2/hour X 8 hrs/day X 250 days)~ $4000
Annual Energy Cost:($0.20 kWh X 480 kWh) ~ $120
Total Annual Cost of Production ~ $4420
Length of Pipe produced per day ~ 220 m Length of Pipe produced per year(250 days) ~ 55000m Number of kits produced per year(kit~20m) ~ 2750
Total Cost Per Kit ~ $1.60
Cost of Operation and Production
($2/hour X 8 hrs/day X 250 days)~ $4000
Total Annual Cost of Production ~ $4420
Length of Pipe produced per day ~ 220 m Length of Pipe produced per year(250 days) ~ 55000m Number of kits produced per year(kit~20m) ~ 2750
Heat Transfer Model
Will temperature at contact Will the heating requirementpoint be high enough? reasonable when considering losses?
Heat in
Yes!
Heat Transfer Model
Will the heating requirement bereasonable when considering losses?
Heat in Heat out
Yes!