CHAPTER 1
INTRODUCTION
1.1 OIL SKIMMER
Oil is one of the most precious crude and being used in many everyday application of human life. Since
most of the oils are poisonous so quite dangerous for alive when it comes to physical contact with them.
Many countries have made strict safety norms for waste water disposal contained with oils mainly
typically from petrochemical and process industries so that such industries are equipped with such kind
of oil skimmer to separate oil from disposal water.
The continuous removal of oil from process fluids, increases the life of fluid; resulting of:
a) Reduction in the machine fluid refilling cost.
b) Improves the disposal water quality.
What is oil skimmer?
It is the process of removing or separating the oil from the oil polluted coolant or oil from oil &
water mixture. The oil and the coolant in the mixed form is collected in the containers. And one of the
following classified methods are adopted to separate the oil from the coolant.
a) By separating the oil from the coolant by aggressively pouring the upper layer of
mixture in the another container
b) By soaking the oil layer using oil soaking element.
c) By skimming oil using flat belt arrangement.
The first two methods are not accurate also these are time consuming and it requires sort of skill
for it’s execution. The later one is simple and the oil can be separated without any fatigue and the
process is accurate.
Figure 1.1 Oil Skimmer
1
1.2 TYPES OF OIL SKIMMER
1. Disc skimmers
2. Drum skimmers
3. Rope skimmers
4. Brush skimmers
5. Belt skimmers
1.2.1. Disc Skimmer
A disc oil skimmer is a device used to remove oil from the surface of water. It operates by
rotating a disc through the contaminated water, where oil adheres to the disc's surface due to the
difference in surface tension between oil and water. As the disc rotates, it moves through a wiper
or scraper that removes the oil from the disc, allowing it to collect in a separate container for
disposal or recycling.
Figure 1.2.1. Disc Skimmer
2
1.2.2. Drum Skimmer
A drum oil skimmer is a device used to remove oil from the surface of water by utilizing a
rotating drum. It is designed to collect oil efficiently in various environments, including industrial
sites, wastewater treatment facilities, and bodies of water affected by oil spills. The drum oil
skimmer operates on similar principles to the disc oil skimmer but uses a cylindrical drum instead
of a flat disc.
Figure 1.2.2. Drum Skimmer
1.2.3 Rope Skimmer
A rope oil skimmer is a type of oil skimming device designed to remove oil from the
surface of water using a continuously moving rope. This method is particularly effective in
environments where traditional skimmers may struggle, such as confined spaces, large surface
areas, or areas with varying water levels. Rope oil skimmers are known for their
simplicity,efficiency, and ability to handle various types of oil.
Figure 1.2.3 Rope Skimmer
3
1.2.4 Brush Skimmer
A brush skimmer is a type of oil skimming device that uses rotating brushes to remove oil
from the surface of water. These skimmers are particularly effective in environments where oil
has mixed with water, forming an emulsified layer that is difficult to separate. Brush skimmers
are versatile, efficient, and can handle various types of oils, including heavy, viscous oils.
Figure 1.2.4 Brush Skimmer
1.2.5 Belt Skimmer
Belt oil skimmer is a device used to remove oil from the surface of water using a
continuously moving belt. It is designed to efficiently collect various types of oil, making it a
versatile and effective solution for different industrial and environmental applications.
Figure1.2.5 Belt Skimmer
4
CHAPTER 2
LITERATURE REVIEW
L. Abdullah et.al (Design And Analyses Of Semi-Automated Portable Oil Spill Skimmer For Water
Treatment Application,2019) have studied Oil spill response action plan is highly critical for preserving
the ecosystem around the oil spillages area. During emergency situation, the action taken need to be
responsive and effective to prevent the spillages from spreading widely and causes more harm to sea and
water creature. Results showed that the prototyped developed passed for the buoyancy force test. The
maximum distance for coverage test using remote control is up to 50 m while it is improved to 60 m via
vision system technique.
S. S. Godawarikar et.al (Oil Recovering Skimmer From The Surface Of Water-IRJET 2020) Nemours
studies has been carried out in the field of oil spill recovery a detailed literature review study has carried
out to understand the how oil skimmers are effectively works. This study is totally based on the how we
recover the oil that has spilled.
Dmitrii Motorin et.al (Journel Of Environmental Management-2022). It allows simulation of the
position and condition of an oil slick, as well as planning of the sequence of movements of a group of
skimmers to respond to a spill based on limited information about weather conditions. Error in the
weather condition measurements has a minor effect on the stability of the solution to the problem;
however, accurate information about the initial position of the spill significantly increases the success of
the oil collection task as well as the volume of oil collected. The response time of the system to the spill
affects the number of skimmers in the event of oil leakage. A higher number of skimmers is calculated
due to the need to collect an oil volume over the periodic release. The system also takes into account the
distance between the oil slick and the base to which the collected oil is transferred.
Philip C. Lewan et al [1992] had studied apparatus for removing oil from the surface of a liquid
using an endless belt partially submerged in the liquid, the belt passes over a primary roller
having a vertical axis and pressure rollers squeeze the belt on the primary roller removing oil
from the belt which allows by gravity to a collection receptacle mounted upon a frame supporting
the primary roller and its drive structure. The belt twists whereby its lower portion submerged in
the liquid denes a reversing loop whose configurations maintained by a weight roller having a
horizontal axis of rotation.
5
Mamta Patel [2015] had studied the function of oil skimmer, its various design aspects and
performance. All the results of experimental studies indicate that slight design improvement of
typical oil skimmers towards to include additional belt shaft and use of belt with steel material
instead of rope; significantly improve the oil recovery efficiency and also its structure became
simpler. As practical overview of different oil spillage cleanup method, this paper has illustrated
several limitations of these methods and current oil spill technology. Further extensive research &
testing can improve the existing techniques and equipment to have better control for oil recovery
exercise. A set of experiments had been conducted by using various oils and different materials of
belt to understand the oil recovery performance and viscosity deviation of oils before and after
separation.
P.A. Patil et al [2017] had concluded that the separation of oil is based on surface tension,
specific gravity and viscosity. He studied the operation of oil skimmer on various positions of the
belt like inclined, vertical, horizontal. The separation of oil is based on surface tension, specific
gravity and viscosity.
Sathiyamoorthy V.et.al(Mobile Oil Skimmer-2017) have studied implemented based on the public
issue which has overcome by our people on January 2017 at Ennore Chennai, Tamilnadu, India. The
oil skimmer is used to separate oil, from mixtures of aqua and oil. It causes highly acidic alkaline
and salty environment remains a great challenge to aquatic organisms and also pollutes the coastal areas.
Every year 706 million gallons of waste oil enters the water resources and pollute the environment. Sea
water has been polluted due to oil spillage; it also affects the water bodies. If the oil spill. Serious
damage to environment. About 90% of contaminated oil can be removed by continuous separation of
oil by skimmer belt. This set-up uses polyurethane belt, bearing, supporting L-angle frame, EN 19 Rod
& Scraper. This work implemented to improve the separation efficiency of the skimmer belt at manual
speeds.
Rashi Yadav.et.al (IOSR JEN-2019) A disc type oil skimmer can be used to separate oil from
water-oil mixture efficiently. The disc when made up of Acrylic gives higher efficiency when
compared to the traditionally used disc made of Mild Steel. Efficiency obtained by using the
Acrylic disc was 88% which is 10% more than the disc made of mild steel. The FEA analysis also
shows that the Acrylic material has enough strength to withstand the forces that act on it. Also,
when the disc is immersed deeper, the volume of the mixture recovered increases, but the quantity
of water recovered also increases thereby decreasing the efficiency. Thus, disc should be
immersed at an optimum depth to get higher efficiency.
6
CHAPTER 3
PROBLEM STATEMENT AND METHODOLOGY
3.1 PROBLEM STATEMENT
Oil leakage in industries and reservoirs must be effectively managed. Oil is
squandered, and the ecosystem is harmed as a result of the spill. It is necessary to
segregate the oil that pollutes the environment.
During the recent decade world has witnessed big oil spillage accidents into ocean
and made huge impactto the environment. Apart this sometime oil is getting
spillage through being the result of chronic and careless habitin the use f oil
industries and oil product.
During the recent decade, World has witnessed big oil spillage accidents into
ocean and made huge impact to the environment. Apart this, sometimes Oil is
getting spillage through being the results of chronic and careless habits in the use
of oil industries and oil products. It is estimated that approximately 706 million
gallons of waste oil enters the ocean every year; whereas more than half of that
sourced from land drainage and waste disposal
3.2 OBJECTIVES OF THE PROJECT
Efficiently separating oil and water to meet environmental standards .
Separating oil from a water solution without dependence on configuration states .
Continuously carrying out extraction separation to ensure continuous chemical
industrial production .
7
3.3 METHODOLOGY OF THE PROJECT
Literature review
Selection of groups of mechanism for the desire motion.
Selection of materials.
Determining the size of the component drawing and sending
for manufacture.
Manufacturing and assembling the product.
Testing of the product for functioning.
Figure 3.1 Methodology of the Project
8
CHAPTER 4
SELECTION OF MATERIALS
4.1 FLAX FIBER
Flax) also known as common flax or linseed, is a member of the genus Linum in
the family Linaceae. It is a food and fiber crop cultivated in cooler regions of the world.
The textiles made from flax are known in the Western countries as linen, and traditionally
used for bed sheets, underclothes, and table linen. The oil is known as linseed oil. In
addition to referring to the plant itself, the word "flax" may refer to the unspun fibers of
the flax plant. The plant species is known only as a cultivated plant, and appears to have
been domesticated just once from the wild species Linumbienne, called pale flax. Flax,
one of the bast types of natural fibres with a good mechanical performance, has been
widely used to produce composites. Contrary to artificial fibres, flax fibres are not
continuous fibres but they have a composite like hierarchically organized structure. Their
macroscopic properties emerge from their micro and nano-structural level (Bos and
Donald, 1999; Thomas and Pothan, 2009). Flax is a fast-growing annual crop and belongs
to the genius of the Linacea family including other bast fibres like hemp, kenaf, and jute.
The morphology of the fibres shows similarities and composites produced using them
show similar properties. The industrially important flax fibres are placed as fibre bundles
in the outer surface of the plant stem as shown in Figure 4.1. The bundles (technical
fibres) are between 60 and 140 cm long and their diameter ranges from 40 to 80 um. The
flax stem contains 20-50 bundles in their cross section.
9
Figure 4.1 Flax Fiber
Table 4.1 Properties of flax fiber
Parameters Values
Density (g/cm3) 1.5
Tensile Strength (Mpa) 800-1500
Specific strength (S/a) 535-1000
Tensile modulus (Gpa) 27.6-80
Specific modulus (E/a) 18.4-53
4.2 BANANA FIBER
Banana nuts are most commonly used as a chewing material in most parts of
China, India, Taiwan, Malaysia, Philippines. The hot-pressed dry leaves of banana trees
are used as disposable leaf platelets and bowls in most places of India. The banana leaves
have 65.8 % hemicellulose as their significant portion along with 12 to 24 % of lignin and
8 to 25 % of water content. The fibers are generally extracted by retting processes, as
discussed earlier. Usually, water retting process is adapted for removing the fibers. The
fibers may be obtained from banana nut, banana sheath and banana leaves. The plant part
from which the fiber has to be extracted is soaked in clean water for about 24 h. After the
immersion time, the fibers are extracted easily from the plant parts and once again washed
with running water to remove sand particles and other contaminants. The weight of the
extracted banana fibres is lower than that of the synthetic fibers.
10
Figure 4.2 Banana Fiber
Table 4.2 Properties of Banana fiber
Parameters Values
Density (g/cm3) 1.34
Tensile strength (MPa) 320 - 876
Young’s modulus (GPa) 42 -48
Elongation at failure (%) 1.47 – 1.48
Elongation at failure (%) 300
4.3 EPOXY RESIN
Epoxy resin (Araldite LY 556) made by CIBA GUGYE Limited, having the
following outstanding properties has been used. Epoxy LY 556 resin, chemically
belonging to the “epoxide' family is used as the matrix material. Its common name is
Bisphenol-A-Diglycidyl-Ether. The low temperature curing epoxy resin (Araldite LY
556) and the corresponding hardener (HY 951) area mixed in a ratio of 10:1 by weight as
recommended. Epoxy is chosen primarily because it happens to the most commonly used
polymer and because of its insulating nature (low value of thermal conductivity, about
0.363 W/m-K).
11
Figure 4.3 Epoxy Resin
4.3.1 Properties of epoxy resin
Excellent adhesion to different materials
Great strength, toughness resistance
Excellent resistance to chemical attack and to moisture
Negligible shrinkage
4.4 TEA WASTE POWDER
Tea fiber is a natural fiber. It has its own natural characteristics and many other
better physical and chemical properties that make it a quality fiber. The following are the
most adorable characteristics of tea fiber
12
Figure 4.4 Tea Waste Powder
4.4.1 Properties of tea waste powder
Low cost
High compressive strength
Low density
High stiffness
Sound and vibration transmitting character
CHAPTER 5
MANUFACTURING PROCESS
In this chapter, the process carried out during the preparation of samples are
explained.
5.1 COMPOSITION RATIO
Table 5.1 Composition Table
13
Sample Tea leaf waste
Flax fibre mat Banana fiber Epoxy resin
number powder
10% 25% 5% 60%
S1
(50 grams) (125 grams) (25grams) (300 grams)
10% 20% 10% 60%
S2
(50 grams) (100 grams) (50 grams) (300 grams)
10% 15% 15% 60%
S3
(50 grams) (75 grams) (75 grams) (300 grams)
10% 10% 20% 60%
S4
(50 grams) (50 grams) (100 grams) (300 grams)
Table 5.2 Composite plate Sample with Abbreviation
Sample No. Abbreviations
S1 B25TW5FX10
S2 B20TW10FX10
S3 B15TW15FX10
S4 B10TW20FX10
Figure 5.1 Fabrication Process
5.2 COMPRESSION MOULDING
14
Compression moulding may follow the first steps of hand lay-up, but normally the
process will be much more complicated. The moulding material, generally preheated, is
first placed in an open, heated mould cavity. The mould is closed with a top force or plug
member, pressure is applied to force the material into contact with all mould areas, while
heat and pressure are maintained until the moulding material has cured.
The mould for a compression-moulded part must be designed for proper routing of
excess resin. A male and female mould will be necessary. They can both be solid moulds
or a bladder mould can be used to compress into the other mould. Once fabrication
techniques have been organized, the production process can begin. First the moulds must
be prepared with a release agent. Then fibers must be cut and placed on the surface of one
or both of the moulds. Catalyzed resin must be impregnated into the fibers with excess.
The two moulds are then joined and adequate pressure can be applied by air or
mechanical force.
a b
Figure 5.2 Compression Moulding Machine
Generally, hydraulic mechanism is used for pressure application in compression
moulding. The controlling parameters in compression moulding method to develop
superior and desired properties of the composite. All the three dimensions of the model
(pressure, temperature and time of application) are critical and have to be optimized
effectively to achieve tailored composite product as every dimension of the model is
equally important to other one. If applied pressure is not sufficient, it will lead to poor
interfacial adhesion of fiber and matrix. If pressure is too high, it may cause fiber
breakage, expulsion of enough resin from the composite system. If temperature is too
high, properties of fiber.
15
CHAPTER 6
WEAR TESTING
A wear test is a method used to evaluate the wear performance and investigate the
wear mechanisms of materials. Wear is the damaging, gradual removal or deformation of
material at solid surfaces. The causes of wear can be mechanical (e.g., erosion) or
chemical (e.g., corrosion). Wear in machine elements, along with other processes such as
fatigue and creep, causes functional surfaces to degrade, eventually leading to material
failure or loss of functionality. There are different types of wear, including adhesive wear,
16
abrasive wear, surface fatigue, fretting wear, erosive wear, corrosion and oxidation wear,
and impact wear. Each type of wear is identified by relative motion, the nature of
disturbance at the worn surface, and whether it affects a self-regenerative or base layer.
One common method of wear testing is the Pin on Disk Test. This test is popular
due to its relative simplicity and the abundance of tribological contacts that can be well
described by a simple pin on disk motion. The stationary pin is pressed against a rotating
disk under a given load. During the test, the friction force, wear, and temperature are
continuously monitored. The test can be performed in dry and lubricated conditions. After
a certain amount of cycles, the test stops and further data processing steps include surface
topography analysis to determine wear volume and surface roughness evolution.
6.1 EXPERIMENTAL PROCEDURE
Initial weight of the pin is measured and then it fits in the specimen holder with the
counter weight applied on the other side of the lever.
The rear disc is fitted perpendicular to the pinned sample which is driven by an
electric motor.
The experimental parameters like wear track diameter, applied load, sliding velocity,
sliding time are set according to our need.
After the experiment is being done the pin is weighed again to find the mass loss. The
data from the computer are used for further analysis.
Figure 6.1 Photographic Views of Pin-On-Disc Apparatus
17
Figure 6.2 Pin-On-Disc Apparatus
CHAPTER 7
COST ESTIMATION
7.1 COST ESTIMATION
The following Table 7.1 shows the cost estimation of the characteristic study of
banana fiber/flax fiber mat/tea waste powder/epoxy resin hybrid composites.
Table 7.1 Cost Estimation of the Material
18
S.NO MATERIAL USED QUANTITY COST (Rs)
1 Banana fiber 4.5 Kg 6,255
2. Epoxy resin 3.5 Lit 2,520
3. Aralydide 200 ml 220
4. Flax fiber 3 Kg 1,800
5. Tea waste powder 3 Kg 580
6. Compression Moulding 12 Nos 3,600
7. Wear Test Samples 12 Nos 7,800
Total 22,775
Cost in words: Twenty Two Thousand Seven Hundred and Seventy Seven.
CHAPTER 8
RESULT AND DISCUSSION
8.1 WEAR TEST AT 10N LOAD
Load – 10 N
Distance – 50 mm
Velocity - 1.8 m/s (in speed 388 rpm)
Table 8.1 Wear test at 10N Load
19
Time in Sec Wear at S1 Wear at S2 Wear at S3 Wear at S4
120 12 18 16 13
240 16 21 17 21
360 19 24 16 22
480 19 26 14 22
600 19 33 14 24
Wear Test at 10N
35
30
25
Wear (µm)
20
15
10
5
0
120 240 360 480 600
Time in Sec
Wear at S1 Wear at S2 Wear at S3 Wear at S4
Figure 8.1 Wear Behaviour at 10N Load
20
8.2 WEAR TEST AT 20N LOAD
Load – 20N
Distance – 50mm
Velocity - 1.8 m/s (in speed 388 rpm)
Table 8.2 Wear test at 20N Load
Time in Sec Wear at S1 Wear at S2 Wear at S3 Wear at S4
120 23 9 10 18
240 30 11 16 25
360 34 16 17 28
480 43 14 16 36
600 41 17 16 37
Wear Test at 20N
50
45
40
35
30
25
20
15
10
0
120 240 360 480 600
Wear at S1 Wear at S2 Wear at S3 Wear at S4
Figure 8.2 Wear Behaviour at 20N Load
8.3 WEAR TEST AT 30N LOAD
21
Load - 30N
Distance - 50mm
Velocity - 1.8 m/s (in speed 388 rpm)
Table 8.3 Wear test at 30N Load
Time in Sec Wear at S1 Wear at S2 Wear at S3 Wear at S4
120 2 2.5 3 2
240 5 2.7 5 4
360 8 2.8 9 1
480 11 2.9 12 1
600 12 2.7 15 1
Wear Test at 30N
14
12
10
0
120 240 360 480 600
Wear at S1 Wear at S2 Wear at S3 Wear at S4
Figure 8.3 Wear Behaviour at 30N Load
8.4 CONCLUSION
22
From the results, it is concluded that for 10 N Load condition the
Sample 3 has the less wear friction due to its reinforcement composition of
10% of flax fibre and 15% of banana fibre and 15% of tea leaf waste powder
and 60% of epoxy resin. For 20N Load condition the Sample 2 and sample 3
has the less wear friction due to its reinforcement composition of 10% of flax
fibre and 10% of banana fibre and 20% of tea leaf waste powder and 60% of
epoxy resin. For 30N Load condition the Sample 3 has the less wear friction
due to its reinforcement composition of 10% of flax fibre and 15% of banana
fibre and 15% of tea leaf waste powder and 60% of epoxy resin.
Banana fiber, flax fiber mat, and tea waste powder possess distinct
physical and mechanical properties that make them suitable candidates for
reinforcing epoxy composites. Surface morphology and chemical composition
analysis have revealed the potential for strong interfacial bonding between the
natural fibers/powder and epoxy matrix, which is essential for enhancing
mechanical performance. Wear tests under simulated conditions have
demonstrated the ability of the composites to resist wear and maintain low
coefficients of friction. The evaluation of wear performances of banana fiber,
flax fiber mat, and tea waste powder reinforced epoxy composites has
demonstrated their potential as sustainable alternatives for various industrial
applications requiring wear-resistant materials. The findings of this study
contribute to the advancement of composite material technology and support
the transition towards environmentally friendly and cost-effective solutions.
Further research and development efforts should focus on scale-up production
processes, optimization for specific applications, and exploration of additional
natural fiber and waste material combinations to expand the range of available
composite options.
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