Acknowledgement

I would like to express my special thanks of gratitude to my teacher Assistant Professor Ashim Roy and
Prof. Sudip Mukherjee who gave me the golden opportunity to do this wonderful project on the topic
(APPLICATION OF TAGUCHI METHOD FOR OPTIMIZATION OF THEORETICAL MODEL OF ELECTRO-
CYCLONE SEPARATOR FOR ARRESTING DIESEL SOOT PARTICULATE MATTER ), which also helped
me in doing a lot of Research and i came to know about so many new things I am really thankful to
them. Secondly i would also like to thank my parents and friends who helped me a lot in finalizing this
project within the limited time frame. Last but not the least thanks to Central Library for providing me
some good information and helped me in doing my project.
 BONAFIDE CERTIFICATE

Certified that this project report titled APPLICATION OF TAGUCHI METHOD FOR OPTIMIZATION
OF THEORETICAL MODEL OF ELECTRO-CYCLONE SEPARATOR FOR ARRESTING DIESEL
SOOT PARTICULATE MATTER is the bonafide work of Aniruddha Das (Reg No:) who carried out
the research under my supervision. Certified further, that to the best of my knowledge
the work reported herein does not part of any other project report or dissertation on the basis of which a
degree or award was conferred on an earlier occasion on this or any other candidate.

Signature
Ashim Roy
Assistant Professor, Mechanical Engineering,
Jalpaiguri Government Engineering College.
Jalpaiguri735102, W.B.,India
Abstract – Diesel soot particulate matter is considered to be the most harmful pollutant as because
the air borne particulate matters are known to constitute a major human risk. Recent epidemiological
studies reported that particles with diameters of less than 2.5 micron are most fetal for living beings due
to inhaling of the same. The reduction of particulate emissions from diesel engine is one of the most
challenging problems in modern society.
The main particulate fraction of diesel exhaust consists of fine particles. Diesel particulate matters are
inhalable and may easily penetrate deep into the lungs because of their small sizes. The rough surfaces
of these particles make it easy for them to bind with other toxins in the environment, thus increasing the
hazards of particle inhalation.
The objective of this study is to illustrate the procedure adopted in using Taguchi Method to a Electro
Cyclone Separator for arresting Diesel soot particulate matter. The orthogonal array, signal-to-noise
ratio, and the analysis of variance are employed to study the performance characteristics on Diesel soot
particulate matter. In this analysis, two factors namely Inlet Velocity and Voltage were considered.
Accordingly, a suitable orthogonal array was selected and experiments were conducted. After
conducting the experiments the surface roughness was measured and Signal to Noise ratio was
calculated. With the help of graphs, optimum parameter values were obtained and the confirmation
experiments were carried out.
 I. Introduction
Diesel soot particulate matter is considered to be the most harmful pollutant as because the air borne
particulate matters are known to constitute a major human risk. Recent epidemiological studies
reported that particles with diameters of less than 2.5 micron are most fetal for living beings due to
inhaling of the same. The reduction of particulate emissions from diesel engine is one of the most
challenging problems in modern society. Diesel particulate emission can easily enter human
respiratory system and are capable of causing cancer because of their association with absorbed and
condensed potential occupational carcinogenic compounds such as poly-nuclear aromatic
hydrocarbon, Nitro–PAH and sulphates. The main particulate fraction of diesel exhaust consists of
fine particles. Diesel particulate matters are inhalable and may easily penetrate deep into the lungs
because of their small sizes. The rough surfaces of these particles make it easy for them to bind with
other toxins in the environment, thus increasing the hazards of particle inhalation. Several solutions
have been proposed to date like ceramic filtration, wire mesh filtration, direct contact type filtration
systems etc., which suffer from high engineering complexity, high costs as well as increased
backpressure. Most of the proposed solutions deteriorate diesel engine combustion performance and
simultaneously increases fuel consumptions.
This paper presents the optimum parameter of a Electro Cyclone Separator by electrostatic
attraction of ultra-fine diesel soot particulate matter for exhaust gas treatment by using Taguchi
Method, This is a Statistical Method developed by Taguchi and Konishi. Initially it was developed
for improving the quality of goods manufactured (manufacturing process development), later its
application was expanded to many other fields in Engineering, such as Biotechnology etc.
Professional statisticians have acknowledged Taguchi‟s efforts especially in the development of
designs for studying variation. Success in achieving the desired results involves a careful selection of
process parameters and bifurcating them into control and noise factors. Selection of control factors
must be made such that it nullifies the effect of noise factors. Taguchi Method involves
identification of proper control factors to obtain the optimum results of the process. Orthogonal
Arrays (OA) are used to conduct a set of experiments. Results of these experiments are used to
analyze the data and predict the quality of components produced. Here, an attempt has been made to
demonstrate the application of Taguchi‟s Method to find the optimum parameter values of Electro
Cyclone Separator for arresting Diesel soot particulate matter.

Fig. 1. Diagrammatic sketch of Electro-Cyclone Separator: (1)particle collecting hoppers;(2)collector wall;(3)impulse

discharge electrode system; (4) dirty gas inlet; (5) clean gas outlet; (6) rapper system
II.FORMULATION OF THE THEORETICAL MODEL
Cyclones have a number of advantages in air sampling, including their relatively low cost of
construction and ease of operation. Since they have no moving parts, their maintenances are very easy.
After all, the cyclones samplers have the highest ratio of performance to energy consumption, compared
to other sampling technologies. Cyclone performance decreases with particle diameter. It has been
demonstrated that particle collection efficiency could be enhanced if electrical forces are applied to
supplement the inertial forces. In electro-cyclone, there is an additional force i.e. electric force, apart
from the centrifugal force and drag force. The electric force is proportional to the product of particle
charge and the strength of the electrostatic field. The movement of a particle is determined by the
balance of the centrifugal force, the drag force and the electric force. The governing forces in an electro-
cyclone separator are Fc (Centrifugal force), Fd (Drag force), Fe (Electrostatic force). In the electro-
cyclone outer vortex fluid field, there are three forces (centrifugal force Fc electrostatic force Fe and drag
force Fd) acting on the particle in the radial direction. The centrifugal force plus electrostatic force are
equal to the drag force acting on the particle at the balance point. The force balance differential
equation can be setup from Newton‟s second law. We get the formula of the differential equation for
particle motion for solid gas separation in a electro-cyclone.

In order to simplify, we can make some assumptions: (1) the particles are dispersed enough and other
effects are ignored; (2) after arriving at the wall of the electrocyclone separator, particles are collected;
no re-entrain occurs; (3) the drag force obeys Stokes‟ law; (4) particles are spherical; and (5) the particle
loading does not affect the gas flow field. Generally, the particle loading is high enough to affect the gas
flow field near the wall of the electrocyclone separator, but the dust concentration in the experiment is
3:5g =Nm 3; and we have assumed that particles are collected and no re-entrain occurs, hence the
assumption seems reasonable.

The driving forces acting on the particles are centrifugal forces, Electrostatic force and Drag force. In
the electro-cyclone outer vortex fluid field, there are three forces (centrifugal force Fc electrostatic force
Fe and drag force Fd) acting on the particle in the radial direction. The centrifugal force plus
electrostatic force are equal to the drag force acting on the particle at the balance point. We get the
formula for particle motion of solid gas separation in a electro cyclone as follows
Centrifugal force + Electrostatic force = Drag Force
FC + Fe = Fd −−−−−−−−−−− (i)

Fig.2 The Forces acting on a particle in Electro-Cyclone Separator

Let us consider that the charged induced on the particle is qes due to local electric field of strength E
(V/m), then the Electrostatic force acting on a particle can be given as

Fe= qes E
Fe= qes −−−−−−−−−−− (ii)
If a particle moves in a circular path in the electro-cyclone separator with radius r and velocity t v along
the path, then the centrifugal force acting on a particle can be calculated as follows:
Centrifugal force

FC = mƒr - mƒc = m(ƒr- ƒc) = ρp [ –r ( ) ] −−−−−−−−−−− (iii)

ƒr = Particle radial acceleration =

ƒc = Particle angular acceleration = r ( )

m = Mass of the particle = ρp
Where, is the soot particulate diameter, ρp is the density of soot particulate matter in kg/m3, vt is the
angular velocity in m/sec. and r is the radius of the electro-cyclone body. According to the Barth model,
it has been assumed that the particle radial velocity was assumed to be zero because of static status.

Hence V r = = 0;

⇒ =0;
Then the equation (i) becomes

FC = [
ρp r ( ) ] −−−−−−−−−−− (iv)
Since r ( ) = Particle tangential velocity ( the same as air tangential velocity Vt can be determined
by the following equations)

( ) =

Research results of Shepherd and Lapple (1939), Ter Linden (1949) and Lieth (1972) indicated that air
stream tangential velocity in the annular section (at the same cross-sectional area) of the cyclone could
be determined by equation

n
Vr =C
Where Vt = Tangential Velocity
r = Air stream radius
n = 0.5 (in outer vortex) – Shepherd and Lapple 1939
C = Constant

For simplicity, it is assumed that Vt equals the average air stream inlet velocity Vin when r equals the
radius of the cyclone well ( R ) that is

Vt r0.5 = Vin R0.5

∴ Vt = ( ) Vin

Therefore, ( ) = ( ) V2 in
Now the equation (iii) can be written as = θ

FC = − ρp ( ) V2 in ------------------------ (v)
But as the soot particles in question are very small (in the order of 1.0μm or less) it is quite natural that
molecular slip will occur, resulting in a lower drag force than that from the above relation. For this
reason the Cunningham‟s Correction Factor „C*‟ is introduced in Drag Force to take into account
molecular slip for very small soot particles in the range mentioned above. Therefore, considering
Correction Factor which is greater than unity acts to decrease the resistance to particle motion, and the
modified drag force becomes as follows. Drag force on a spherical particle may be determined by the
Stokes law. By introducing Cunningham‟s slip correction factor for molecular slip we get the expression
for drag force as

( )
Drag force Fd =

{ ( )}
Fd =

{ ( )}
Fd = ----------------------- (vi)

C* = 1+2 (1.257 0.400e – 0.55dp/ λ ) [W. Strauss, 1966(80)]

= &̅ √

Where
C* = Cunningham‟s Correction Factor
ū = Mean molecular velocity of the particle
μ= Dynamic viscosity of diesel engine exhaust
( )= Relative radial velocity of particle
Vr = Particle radial velocity =
[Where r be any radial distance from the centre of the vortex]
Vgr = Air stream radial velocity

Basically the static particle theory suggested that the critically sized particle (d50) is smaller than the
smallest particle, which is collected, and larger than the largest particle that penetrates the cyclone.
Particles with diameter of d50 theoretically suspends in the outer vortex due to the force balance. Even
though there is a d50 distribution in the outer space, only those d50 on the interface of inner vortex and
outer vortex will characterize the electro-cyclone performance and represent the cut-point of the electro-
cyclone. To solve the force balance differential equation (4), Barth made several assumptions:
1. The particle radial velocity was assumed to be zero because of static status.
⇒( πDc3 ρpVin2C)dp3 +( μabVin Dc2 ) dp2+ ( qesDc3VC) dp = 0 −−−−−−−(iv)

Parameter taken for performing Taguchi Analysis are given in the tabular form:

Parameters Values References

Allowable pressure drop <300 mbar,3000(pa) <400 mbar, Dementhon and Martin(1997)
4000(pa)
Temperature (100-500) degree Celsius Luders et al.(1999)
Density of soot particle (2000-1600) kg/m3 Horiuchi et al.(1990)
Exhaust viscosity 2.97/10^6 kg/ms Muntean(1990)
Exhaust density (0.501-0.54) kg/m3 Suresh et al. (2000)
Volume flow rate (0.02-0.40) m3/sec Suresh et al. (2000)
Aerodynamic equivalent (1-10) micron Mayer et al. (1995)
diameter [AED] Dementhon Martin (1997)
Diesel particulate diameter <=(0.1-1) micron, <1 mm
Khalil and Levendis (1992)

Theoretical Particle Collection Efficiency:

Particle collection efficiency, η is defined as the percentage of particles in number collected by the
electro cyclone over the total number of particles entering the electro cyclone separator.
Lapple (1950) found a correlation between the collection efficiency and which was shown
by Theodore and Depaola (1980) to be:
η= Where Dp50 is calculated by equation (iv). Assuming Dp = 0.1 micron

II. Approach to Process Development

The technology of the combination of the cyclone, electrostatic attraction has been applied in exhaust
gas treatment . The significant increases of collecting efficiency of electro-cyclone with the help of
electrostatic attraction have been demonstrated. The state of the art analysis orientate us to make the
choice of two technologies : cyclone plus electrostatic precipitation.
This paper present the study of the electro-cyclone separator‟s collection efficiency.
 2.1 Design of Experiments
The Design of Experiments is considered as one of the most comprehensive approach in
process developments. It is a statistical approach that attempts to provide a predictive knowledge
of a complex, multi-variable process with few trials. Following are the major approaches to
DOE:
2.1.1 Taguchi Method
The Full Factorial Design requires a large number of experiments to be carried out as
stated above. It becomes laborious and complex, if the number of factors increase. To overcome
this problem Taguchi suggested a specially designed method called the use of orthogonal array to
study the entire parameter space with lesser number of experiments to be conducted. Taguchi
thus, recommends the use of the loss function to measure the performance characteristics that are
deviating from the desired target value. The value of this loss function is further transformed into
signal-to-noise (S/N) ratio. Usually, there are three categories of the performance characteristics
to analyze the S/N ratio. They are: nominal-the-best, larger-the-better, and smaller-the-better.

III. Steps Involved in Taguchi Method

The use of Taguchi‟s parameter design involves the following steps.
a. Identify the main function and its side effects.
b. Identify the noise factors, testing condition and quality characteristics.
c. Identify the objective function to be optimized.
d. Identify the control factors and their levels.
e. Select a suitable Orthogonal Array and construct the Matrix
f. Conduct the Matrix experiment.
g. Examine the data; predict the optimum control factor levels and its performance.
h. Conduct the verification experiment.

IV. Approach to the Experimental Design

In accordance with the steps that are involved in Taguchi‟s Method, a series of experiments are to be
conducted. Here, facing operation on mild steel components using a lathe has been carried out as a case
study. The procedure is given below.

4.1 Identification of Main Function and its side effects

Main function: Collection Efficiency of Electro Cyclone Separator w.r.t Optimum Values
of Inlet Velocity of Exhaust gas and Applied Voltage
Side effects : Excessive Heat Production, Back Pressure on Engine, Carbon Particle
Concentration on Electrode.
Before proceeding on to further steps, it is necessary to list down all the factors that are going to affect
or influence the facing process and from those factors one has to identify the control and noise factors.
The “Factors” that affect facing operation on a lathe machine are listed in the table 4.1.
 Table 4.1: Factors that affect facing operation
Control factors Noise Factors

Inlet Velocity Back Pressure

Applied Voltage Temperature
Flow Rate Matter Concentration
Inlet Cross-section Vortex Disturbance
Cyclone Diameter Vortex Formation

After listing the control and the noise factors, decisions on the factors that significantly affect the
performance will have to be ascertained and only those factors must be taken in to consideration in
constructing the matrix for experimentation. All other factors are considered as Noise Factors.

4.2 Identifying the Testing Conditions and Quality Characteristics To Be Observed

Quality Characteristic: Collection Efficiency of Electro Cyclone Separator

Cyclone material: Aluminum
Input Voltage: 12V DC
Testing Equipment: Smoke Meter

4.3 Identify The Objective Function

Objective Function: Smaller-the-Better

2
S/N Ratio for this function: : ɳ= -10 log10( ∑i=1 y i )
Where, n= Sample Size, and y= Efficiency in that Run

4.4 Identifying the Control Factors and their levels

The factors and their levels were decided for conducting the experiment, based on a “brain
storming session” that was held with a group of people and also considering the guide lines given in the
operator‟s manual provided by the manufacturer of the lathe machine. The factors and their levels are
shown in table 4.2.

FACTORS LEVELS
LOW(1) Medium(2) High(3)
Vint (m/s) 36 46 66
V(Voltage) 600 850 1350
Table 4.2 Selected Factor and their levels

4.5 Selection of Orthogonal Array

To select an appropriate orthogonal array for conducting the experiments, the degrees of freedom
are to be computed. The same is given below:
Total Degrees of Freedom: 9
 The most suitable orthogonal array for experimentation is L9 array as shown in Table 4.3[5].
Therefore, a total nine experiments are to be carried out.

Table 4.3 Orthogonal Array (OA) L9

EXP. NO, CONTROL FACTORS
1 2
1. 1 1
2. 1 2
3. 1 3
4. 2 1
5. 2 2
6. 2 3
7. 3 1
8. 3 2
9. 3 3

4.6 Conducting The Matrix Experiment

In accordance with the above OA, experiments were conducted with their factors and their levels
as mentioned in table 4.2. The experimental layout with the selected values of the factors is shown in
Table 4.4. The table 4.5 shows the measured values of Collection Efficiency of Electro Cyclone
Separator obtained from different experiments.

Table 4.4: OA with Control Factor

EXP. NO, CONTROL FACTORS
vint (m/s) V(Voltage)
1. 36 600
2. 36 850
3. 36 1350
4. 46 600
5. 46 850
6. 46 1350
7. 66 600
8. 66 850
9. 66 1350

Table 4.5 Measured values of Collection Efficiency of Electro Cyclone Separator

Experiment No. Efficiency (yi)*
1. 0.80638
2. 0.80638
3. 0.80638
4. 0.730929
5. 0.730929
6. 0.730929
 7. 0.639531
8. 0.639531
9. 0.639531

4.7 Examination of Data

The following are the experimental results of the work carried out.
4.7.1 Experimental Details
Since the objective function (Surface Finish) is smaller-the-better type of control function, was
used in calculating the S/N ratio. The S/N ratios of all the experiments were calculated and tabulated as
shown in Table 4.6.
Table 4.6 Tabulated S/N ratios
Experiment No. S/N Ratio(dB)
1. 0.934602522
2. 0.934602522
3. 0.934602522
4. 1.361248069
5. 1.361248069
6. 1.361248069
7. 1.941383991
8. 1.941383991
9. 1.941383991

The S/N ratio for the individual control factors are calculated as given below:
Svint1=(η₁+η₂+η3),
S vint2=(η4+η5+η6) &
S vint3=(η7+η8+η9)
And For Voltage
SV1=(η₁+η4+η7),
SV2=(η2+η5+η8)
SV3=(η3+η6+η9)
For selecting the values of η₁, η2, η3 etc. and to calculate Svint1, Svint2 & Svint3 see table 4.3.
ηk is the S/N ratio corresponding to Experiment k.
Average S/N ratio corresponding to Inlet Velocity at level 1 = Svint1/3
Average S/N ratio corresponding to Inlet Velocity at level 2 = Svint2/3
Average S/N ratio corresponding to Inlet Velocity at level 3 = Svint3/3
j is the corresponding level each factor. Similarly SVj is calculated for Voltage. The average of the
signal to noise ratios is shown in table 4.7. Similarly S/N ratios can be calculated for other factors.

Table 4.7: Average S/N Ratios for each factor

Level Vint (m/s) V(Voltage)
Sum(Svj) Avg S/N Sum(SVj) Avg S/N Ratio
Ratio
1 2.803807567 0.934602522 4.237235 1.412411527
2 4.083744207 1.361248069 4.237235 1.412411527
3 5.824151973 1.941383991 4.237235 1.412411527
 3.5 1.6
3 1.4
2.5 1.2
1
S/N(dB)

S/N(dB)
2
0.8
1.5
0.6
1 0.4
0.5 0.2
0 0
1 2 3 1 2 3
Level Levels

Fig-1 Charts Showing Parameter Level v/s S/N Ratio

Table 4.8 Optimum values of factors and their levels

Parameter Optimum Value Level
Vint (m/s) 36 1
V(Voltage) 600 1

ANNOVA Analysis and It’s Significance

The one-way analysis of variance (ANOVA) is used to determine whether there are any statistically
significant differences between the means of three or more independent (unrelated) groups.

The one-way ANOVA compares the means between the groups you are interested in and determines
whether any of those means are statistically significantly different from each other. Specifically, it tests
the null hypothesis:

where µ = group mean and k = number of groups. If, however, the one-way ANOVA returns a
statistically significant result, we accept the alternative hypothesis (HA), which is that there are at least
two group means that are statistically significantly different from each other.

At this point, it is important to realize that the one-way ANOVA is an omnibus test statistic and cannot
tell you which specific groups were statistically significantly different from each other, only that at least
two groups were. To determine which specific groups differed from each other, you need to use a post
hoc test
In Next Step design is to recruit a group of individuals and then split them into groups based on some
independent variable. Again, each individual will be assigned to one group only. This independent
variable is sometimes called an attribute independent variable because you are splitting the group based
on some attribute that they possess (e.g., their level of education; every individual has a level of
education, even if it is "none"). Each group is then measured on the same dependent variable having
undergone the same task or condition (or none at all). For example, a researcher is interested in
determining whether there are differences in leg strength between amateur, semi-professional and
professional rugby players. The force/strength measured on an isokinetic machine is the dependent
variable.
One – Way Annova Analysis

Treatments

1 2 Total

N 3 3 6

∑X 148 2800 2948

Mean 49.3333 933.3333 491.3333

∑X2 7768 2905000 2912768

Std.Dev. 15.2753 381.8813 541.1686

Result Details
Source SS df MS

Between- 1172184 1 1172184

treatments

Within- 292133.3333 4 73033.3333 F = 16.04999

treatments
Total 1464317.3333 5

The f-ratio value is 16.04999. The p-value is .016047. The result is significant at p < .05.

Conclusion :
This paper illustrates the application of the parameter design (Taguchi method) in the optimization of
Electron Cyclone Separator. The following conclusions can be drawn based on the above experimental
results of this study:
- Analytical approach for collection efficiency of electro-cyclone separator as a Diesel particulate
filter considering external applied electric field have been proposed.
- Electro cyclone separator studies as a Diesel Engine soot particulate emission arrester is
presented.
- Taguchi‟s Method of parameter design can be performed with lesser number of experimentations
as compared to that of full factorial analysis and yields similar results.
- Taguchi‟s method can be applied for analyzing any other kind of problems as described in this
paper.
- It is found that the parameter design of the Taguchi method provides a simple, systematic, and
efficient methodology for optimizing the process parameters.
NOTATION:
A: Inlet cross sectional area of electro-cyclone flow [m2]
a: Inlet height of the electro-cyclone [m]
b: Inlet width of the electro-cyclone [m]
DC : Diameter of electro cyclone separator [m]
: Outer diameter of the cyclone [m]
D: Diameter of the vortex finder [m]
: Diameter of the dust exit [m]
D0 : Inner vortex core diameter [m]
Dp50 : Cut size diameter of the particle [μm]
𝑑 : Diameter of soot particle [μm]
: Centrifugal force [N]
: drag force acting on the particle [N]
: Electrostatic force acting on the particle [N]
E: Electric field strength [Volt/m]
: Charged induced on the particle [Culomb]
𝑉 : Voltage applied [Volt]
Vt : Tangential Velocity of exhaust Gas [m/sec]
Vr : Radial velocity of particle [m/sec]
Vin : Inlet Velocity of exhaust gas [m/sec]
Vgr : Air stream radial velocity [m/sec]
λ : Mean free path of the particle[m]
M : Mass of the particle R: Radius of electro-cyclone well [m]
𝐿1 : Length of the cylindrical portion of the cyclone [m]
n: vortex exponent
T: exhaust gas temperature in K
: Number of particles remains in the outer vortex at an angle of turn θ Q: volume flow
rate [m3/sec]
r : Radius of electro-cyclone separator [m]
t: Temperature of the exhaust gas [0C]
: Density of the exhaust gas [kg/m3]
: Density of the particle [kg/ m3]
η : Collection efficiency electro-cyclone separator
μ: dynamic viscosity of the gas [kg/m-sec]
θ: Angle of turn in traversing the cyclone [rad]
: Universal gas constant, in N-m/kmolk
Z0 : Electro-cyclone effective length [m]
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