8/19/2019 Project on Plastic to Fuel
1/60
Plastic To Fuel Machine ProjectReport2014
1
A PROJECT REPORT ON
PLASTIC TO FUEL MACHINE
2014
Submitted in partial fulfilment of the requirements for theaward of the degree of
Bachelor of Technology in
Polymer Engineering of Mahatma Gandhi University
BY
AJMAL ROSHAN T. J, SWATHI E& SANJAY R.
Department of Polymer Engineering
Mahatma Gandhi University College of Engineering
Muttom P. O, Thodupuzha, Kerala–685 587
8/19/2019 Project on Plastic to Fuel
2/60
Plastic To Fuel Machine ProjectReport2014
2
MAHATMA GANDHI UNIVERSITY COLLEGE OF ENGINEERING
Muttom P.O, Thodupuzha, Kerala–685 587
DEPARTMENT OF POLYMER ENGINEERING
CERTIFICATE
This is to certify that the report entitled “PLASTIC TO FUELMACHINE”,
submitted by AJMAL ROSHAN T. J.(Reg.No.10018674), SWATHIE.(Reg.No.10018699)& SANJAY R. (Reg.No.10018692) to theDepartment of Polymer Engineering, MahatmaGandhi University Collegeof Engineering, Thodupuzha, in partial fulfilment oftherequirements for the award of the degree of Bachelor ofTechnology in Polymer Engineeringfrom Mahatma Gandhi University,Kottayam, Kerala, is an authentic report of the project
presented by them during the academic year2013-2014.
Dr. Josephine George
Head of the Department
Polymer Engineering
8/19/2019 Project on Plastic to Fuel
3/60
Plastic To Fuel Machine ProjectReport2014
3
ACKNOWLEDGEMENT
The successful completion of any task is incomplete if we do notmention
the people who made it possible. It is a Great pleasure toexpress our sincere
gratitude to Prof. K.T. SUBRAMANIAN, Principal, MGUCE, forhis
guidance, advice and encouragement.
We are greatly indebted to Dr. Josephine George, Head of the
Department of Polymer Engineering, for her valuable help andguidance at
different stages of this work.
We thank all the faculty and staff of Polymer Engineeringdepartment,
faculties of fuel testing lab at National Institute ofTechnology- Calicut, our
friends and family for their support and constant encouragementthroughout this
work.
Above all we thank GODalmighty without whom this taskwould not
have been a success.
AJMAL ROSHAN T. J, SWATHI E& SANJAY R.
8/19/2019 Project on Plastic to Fuel
4/60
Plastic To Fuel Machine ProjectReport2014
4
About the Team
1. Dr. Josephine George
H.O.D.
Polymer Engineering,
Mahatma Gandhi University College of Engineering,Thodupuzha.
2.
AJMAL ROSHAN T. J.
THAMARATH HOUSE
PALAYOOR CHURCH ROAD
CHACVAKKAD P.O.
THRISSUR-680506
E- mail:[emailprotected]
Mob: 9961161870
3. SANJAY R.
MENASSERIL HOUSE
C.M.C-1,
CHER THALA P.O.
ALAPUZHA-688524
E- mail:[emailprotected]
Mob:- 9995069478
4. Swathi E.
E-mail: [emailprotected]
mailto:[emailprotected]:[emailprotected]:[emailprotected]:[emailprotected]:[emailprotected]:[emailprotected]:[emailprotected]:[emailprotected]
8/19/2019 Project on Plastic to Fuel
5/60
Plastic To Fuel Machine ProjectReport2014
5
CONTENTS
1. Abstract…………………………………………………………………..7
2. Introduction
2.1. Plastics…………………………………….………...……………….8
2.2. Common Plastic Uses…….………………………………………….9
2.3. Special-Purpose Plastics……….…………………………………...10
2.4. Advantages of Plastic………………………..……………………...11
2.5. Disadvantages of Plastic……………………….……………………11
2.6. Plastic Production, Consumption andGrowth……….……….......12
2.7. Plastics in Procurement………….…….…………………..………13
2.8. Manufacture………………………….…………...…………...…....13
2.9. Health Impacts ofManufacture…..……………...…...…….…......14
2.10. Sources and Types of PlasticWastes…………….………….…...15
2.11. Plastic Waste Recycling………………………...…………….…..16
2.12. Some Attempts for Plastic Recycling……..……………………...18
2.13. Alternative Methods…………………..……………………….....20
3. Objective…………………………………..…………..………………...22
4. Experimental details
4.1. Principles of the Machine………………………………...…..…22
8/19/2019 Project on Plastic to Fuel
6/60
Plastic To Fuel Machine ProjectReport2014
6
4.2. Process Carried Out in the Machine
4.2.1. Pyrolysis………………………………………...…………23
4.2.2. Process…………………………………………………..…23
4.3. Parts of the Machine
4.3.1 Reactor………………...……………….…………….…….24
4.3.2. Catalytic cracker………………………..………….……..26
4.3.3. Condenser…………….…………………………….……..27
4.3.4. Nitrogen Cylinder….……………………………………..28
4.4.Materials used…….…………………...……………….…………28
4.5. Laboratory Set Up……………………………………………….30
4.6. Process to be carried out………………...……….……..……….31
4.7. Inferences Drawn From Experiment…..………….……….…...32
5. Test for Characterizing Output
5.1. Calorific Value……………..……………………………….……33
5.1.1 Principle………………………………….……..………….33
5.1.2. Procedure……………..…..………………...……………..34
5.1.3. Calculations……………………...………...…………...….35
5.2. Viscosity………………………………………………...…………36
5.3. Acidity (Acid value)
5.3.1. Definition…….…………………………....………..…..….37
8/19/2019 Project on Plastic to Fuel
7/60
Plastic To Fuel Machine ProjectReport2014
7
5.3.2. Procedure……….…...……………………...........….…….38
5.4. Density and SpecificGravity.……………………..…..….……..38
6. Results and Discussions
6.1. Test Results
6.1.1. Calorific Value………………………..………..…..……40
6.1.2. Viscosity…………….………………………….…………42
6.1.3. Acidity (Acidvalue)..........................................................44
6.1.4. Density and Specific Gravity……………..……..…..….46
6.2. Role of Catalyst in the process……..…....….…..…………….50
6.3. Molecular Structure of the Catalyst….……….…………….51
6.4 Process taking place in a Catalytic Reactor……...………….51
6.5. Features of Catalyst to be used…………..……….…….…….52
6.6. Cracking of Molecules in Reactor in Presence ofCatalyst....53
6.7. Regeneration of catalyst………………………...…………….53
6.8. Need of Catalytic Cracking………...……….………………...54
7. Conclusion…………………………………………………..………..….55
8. References…………………………………………………….…............56
9. Certifications,……………………………………………………………58
8/19/2019 Project on Plastic to Fuel
8/60
Plastic To Fuel Machine ProjectReport2014
8
1. ABSTRACT
Polymers are finding extensive application in our day to daylife. The
low density, high strength to weight ratio, ease of processingetc. make them attractive over
other conventional materials. The various fields of applicationsof polymers includes different
sectors such as structural and non-structural, automobile,medical, aerospace etc. Extensive
use results in accumulation of waste plastics. The safe disposalof waste plastics is a major
problem faced by the polymer industry. The combustion ofpolymers can release so many
toxic gases to the atmosphere and can lead to majorenvironmental hazards. Since crude oil is
the starting material for the production of plastic, the reverseprocessing of plastic back to
crude oil is an innovative method for better disposal ofplastics. Waste plastics are heated in a
reactor at a temperature of about 350- 450℃provided withan inert atmosphere. The waste
plastics used include, Polyethylene (PE), Polypropylene(PP), and Polystyrene (PS). The long
chain molecules of these plastics is first broken into shorterchain molecules in the reactor
and then broken into small molecules in the catalytic cracker.The final product is mixed oil
that consists of gasoline, diesel oil, kerosene and the like.The machine and process for
making oil are totally based on environment-friendly concept.Plastics suitable for converting
into oil are PP (Garbage bag, cookie bag, CD case, etc.), PE(Vinyl bag, medical product, cap
of PET bottle etc.) and PS (Cup Noodle Bowl, lunch box,Styrofoam etc.).
8/19/2019 Project on Plastic to Fuel
9/60
Plastic To Fuel Machine ProjectReport2014
9
2. INTRODUCTION
2.1. Plastics
As a brief introduction to plastics, it can be said thatplastics are
synthetic organic materials produced by polymerization. They aretypically of high molecular
mass, and may contain other substances besides polymers toimprove performance and/or
reduce costs. These polymers can be moulded or extruded intodesired shapes. Plastic is the
general common term for a wide range of synthetic orsemi-synthetic organic amorphous
solid materials used in the manufacture of industrial products.Plastics are typically polymers
of high molecular mass, and may contain other substances toimprove performance and/or
reduce costs. Monomers of Plastic are either natural orsynthetic organic compounds. The
word is derived from the Greek past (plastikos) meaning fit formoulding, and past (plastos)
meaning moulded. It refers to their malleability or plasticityduring manufacture that allows
them to be cast, pressed, or extruded into a variety of shapessuch as films, fibres, plates,
tubes, bottles, boxes, and much more. The common word plasticshould not be confused with
the technical adjective plastic, which is applied to anymaterial which undergoes a permanent
change of shape (plastic deformation) when strained beyond acertain point. Aluminium, for
instance, is plastic in this sense, but not a plastic in thecommon sense; in contrast, in their
finished forms, some plastics will break before deforming andtherefore are not plastic in the
technical sense. There are two main types of plastics:thermoplastics and thermosetting
polymers.
Thermoplastics can repeatedly soften and melt if enoughheat is applied and hardened
on cooling, so that they can be made into new plastics products.Examples arepolyethylene, polystyrene and polyvinyl chloride,among others.
Thermosets or thermosettings can melt and take shape onlyonce. They are not
suitable for repeated heat treatments; therefore after they havesolidified, they stay
solid. Examples are phenol formaldehyde and ureaformaldehyde
8/19/2019 Project on Plastic to Fuel
10/60
Plastic To Fuel Machine ProjectReport2014
10
2.2. Common Plastic Uses Polypropylene(PP) - Foodcontainers, appliances, car fenders (bumpers), plastic
pressure pipe systems.
Polystyrene(PS) -Packaging foam, food containers,disposable cups, plates, cutlery,
CD and cassette boxes.
High impact polystyrene (HIPS) - Fridge liners, foodpackaging, vending cups.
Acrylonitrile butadiene styrene (ABS)
Electronic equipment cases (e.g., computer monitors, printers,keyboards), drainage
pipe
Polyethylene terephthalate (PET)
Carbonated drinks bottles, jars, plastic film, microwavablepackaging.
Polyester (PES)
Fibers,textiles.
Polyamides (PA) (Nylons)
Fibers, toothbrush bristles, fishing line, under-the-hood carengine mouldings. Polyvinyl chloride (PVC)
Plumbing pipes and guttering, shower curtains, window frames,flooring.
Polyurethanes (PU)
Cushioning foams, thermal insulation foams, surface coatings,printing rollers.
(Currently 6th or 7th most commonly used plastic material, forinstance the most
commonly used plastic found in cars).
Polyvinylidene chloride (PVDC) (Saran)Foodpackaging.
Polyethylene (PE)
Wide range of inexpensive uses including supermarket bags,plastic bottles.
Polycarbonate/Acrylonitrile Butadiene Styrene(PC/ABS)
A blend of PC and ABS that creates a stronger plastic. Used incar interior and
exterior parts,and mobile phone bodies.
8/19/2019 Project on Plastic to Fuel
11/60
Plastic To Fuel Machine ProjectReport2014
11
2.3. Special-Purpose Plastics:
Polymethyl methacrylate (PMMA)
Contact lenses, glazing (best known in this form by its varioustrade names around the
world; e.g., Perspex, Oroglas, Plexiglas), aglets, fluorescentlight diffusers, rear light
covers for vehicles.
Polytetrafluoroethylene (PTFE)
Heat-resistant, low-friction coatings, used in things likenon-stick surfaces for frying
pans, plumber's tape and water slides. It is more commonlyknown as Teflon.
Polyetheretherketone (PEEK) (Polyetherketone)
Strong, chemical- and heat-resistant thermoplastic,biocompatibility allows for use in
medical implant applications, aerospace mouldings. One of themost expensive
commercial polymers.
Polyetherimide (PEI) (Ultem)
A high temperature, chemically stable polymer that does notcrystallize.
Phenolics (PF) or (phenol formaldehydes)
High modulus, relatively heat resistant, and excellent fireresistant polymer. Used for
insulating parts in electrical fixtures, paper laminatedproducts (e.g., Formica),
thermally insulation foams. It is a thermosetting plastic, withthe familiar trade name
Bakelite, that can be moulded by heat and pressure when mixedwith a filler-like
wood flour or can be cast in its unfilled liquid form or cast asfoam (e.g., Oasis).
Problems include the probability of mouldings naturally beingdark colours (red,
green, brown), and as thermoset difficult to recycle.
Urea-formaldehyde (UF)
One of the aminoplasts and used as a multi-colorable alternativeto phenolics. Used as
a wood adhesive (for plywood, chipboard, hardboard) andelectrical switch housings.
Melamine formaldehyde (MF)
One of the aminoplasts, and used as a multi-colorablealternative to phenolics, for
instance in mouldings (e.g., break-resistance alternatives toceramic cups, plates and
bowls for children) and the decorated top surface layer ofthe paper laminates (e.g.,
Formica).
8/19/2019 Project on Plastic to Fuel
12/60
Plastic To Fuel Machine ProjectReport2014
12
Polylactic acid (PLA)
A biodegradable, thermoplastic found converted into a variety ofaliphatic polyesters
derived from lactic acid which in turn can be made byfermentation of various
agricultural products such as corn starch, once made from dairyproducts
2.4. Advantages of Plastic:
1) They are light in weight.
2) They are strong, good and cheap to produce.
3) They are unbreakable
4) Used to make - Water bottles, pens, plastic bags, cupsetc.
5) They are good water resistant and have good adhesiveproperties.
6) They can be easily moulded and have excellentfinishing
7) They are corrosion resistant.
8) They are chemical resistant
9) Plastic is used for building, construction,electronics, packaging and transportation
industries.
10)They are odourless.
2.5. Disadvantages of Plastic:
1) They are non renewable resources.
2) They produce toxic fumes when burnt.
3)
They are low heat resistant and poor ductility.
4) They are non biodegradable.
5) They harm the environment by choking the drains.
6) The poisonous gaseous product produced by thedecomposition plastic can causes
CANCER
7) They are embrittlement at low temperature anddeformation at high pressure.
8) The recycling of plastic is not cost effective processand even more expensive
compare to its manufacturing.
8/19/2019 Project on Plastic to Fuel
13/60
Plastic To Fuel Machine ProjectReport2014
13
9) Plastic materials like plastic bags are mostly end upas harmful waste in landfill which
may pollute the environment and threatening our health.
10)The biodegradation of plastic takes 500 to 1,000 yearsJapan
2.6. Plastic Production, Consumption and Growth
Economic growth and changing consumption and production patternsare
resulting into rapid increase in generation of waste plastics inthe world. In Asia and the
Pacific, as well as many other developing regions, plasticconsumption has increased much
more than the world average due to rapid urbanization andeconomic development. The
world‟s annual consumption of plastic materials has increasedfrom around 5 million tonnes
in the 1950s to nearly 100 million tonnes; thus, 20 times moreplastic is produced today than
50 years ago. This implies that on the one hand, more resourcesare being used to meet the
increased demand of plastic, and on the other hand, more plasticwaste is being generated.
Due to the increase in generation, waste plastics are becoming amajor stream in solid waste.
After food waste and paper waste, plastic waste is the majorconstitute of municipal and
industrial waste in cities. Even the cities with low economicgrowth have started producing
more plastic waste due to plastic packaging, plastic shoppingbags, PET bottles and other
goods/appliances using plastic as the major component. Thisincrease has turned into a major
challenge for local authorities, responsible for solid wastemanagement and sanitation. Due to
lack of integrated solid waste management, most of the plasticwaste is neither collected
See AlsoManual de Aire Comprimido ATLAS COPCO - [PDF Document]Enzyme Immobilization - [DOCX Document]US Patent Application for SYSTEM AND PROCESS FOR RECOVERING METHANE AND CARBON DIOXIDE FROM BIOGAS AND REDUCING GREENHOUSE GAS EMISSIONS Patent Application (Application #20210221755 issued July 22, 2021)Lou Henry Hoover & Stanford University : CSPAN2 : June 2, 2024 12:29am-1:14am EDT : Free Borrow & Streaming : Internet Archiveproperly nor disposed of in appropriate manner to avoidits negative impacts on environment
and public health and waste plastics are causing littering andchocking of sewerage system.
The World's annual consumption of plastic materials hasincreased from around 5 to nearly
100 million tonnes in the last 50 years, with plastic being thematerial of choice in nearly half
of all packaged goods. The poverty-related impacts arising fromplastics are complex and lie
in the areas of health and disposal and they mainly occur inparts of the developing world. In
addition, plastic production use and disposal also has a rangeof environmental impacts which
has been the focus of much concern from NGOs, scientists andpolicy makers. There are also
crosscutting poverty, health and social issues related toplastics.
8/19/2019 Project on Plastic to Fuel
14/60
Plastic To Fuel Machine ProjectReport2014
14
2.7. Plastics in Procurement
Plastic is a miracle material that has supported and driveninnovation in the
supply and delivery of products, but also a problematicsubstance that uses non-renewable
resources, creates pollution in manufacture and use and presentsa global issue for disposal.
Plastics are found in a vast range of products, either as aprimary material or as a component.
Plastics have also, due to reasons of weight, flexibility,usability and cost, become a primary
material used for packaging, containers, furniture andconstruction materials. As a result of
this diverse range of uses it is likely that many procurementactivities will involve the
purchase of plastics either directly or indirectly.
2.8. Manufacture
The vast majority of plastics are produced from the processingof
petrochemicals (derived from crude oil). In the US,plastic manufacture (as a feedstock and
energy source) is estimated to consume approximately 4.6% oftotal oil consumption (US
Energy Information Association, 2009). Petrochemical basedplastics are manufactured
through the “cracking” of oil and natural gas in order toproduce different hydrocarbons.
These are chemically processed to produce monomers (smallchemical molecules that can
bond with others) which then undergo a polymerisationprocess (bonding with other
monomers into long chain chemicals) to produce polymers. Theseundergo further
processing, normally using additives to change their“feel”, colour or performance, to
produce feedstock. Usually in the form of pellets, thiscan be transported and further
processed through heat and moulding to make finishedproducts. As with any heavy industrialprocess, plasticsmanufacture can give rise to a range of environmental and socialimpacts,
some of which can give rise to poverty considerations. Pollutionof water courses and local
air quality impacts in parts of the developing world candirectly affect the quality of life and
opportunities of local people, as they often depend upon fishingand hunting for their
livelihoods.
8/19/2019 Project on Plastic to Fuel
15/60
8/19/2019 Project on Plastic to Fuel
16/60
Plastic To Fuel Machine ProjectReport2014
16
Figure 1: Plastic waste are used for land filling.
2.10. Sources and Types of Plastic Wastes
Plastic wastes arise from different sources, commercial,industrial, household, construction,demolition, radioactive andhospital wastes. Plastic in commercial wastes, such as fromretailstores and offices, are managed alone with other wastes fromtheir sources and usuallycombined with household wastes. Specialsource of plastic waste is discarded agriculturemulch (film).
Table 1: Plastics and their products
Sl. No. Types of plastics Industries1 High DensityPolyethylene
(HDPE)
Plastic containers
2 Low Density Polyethylene (LDPE) Milk bags and otherpackaging
materials
3 Polypropylene (PP) Plastic ropes and cups
8/19/2019 Project on Plastic to Fuel
17/60
Plastic To Fuel Machine ProjectReport2014
17
Apart from these, we do use polymers as coating material inpaint industries and adhesive
industries but these do not come as a plastic waste. The varioussource of plastics wastes are
given below:
Table 2: Waste generation from plastics
2.11. Plastic Waste Recycling
On the other hand, plastic waste recycling can provide anopportunity to
collect and dispose of plastic waste in the most environmentalfriendly way and it can beconverted into a resource. Thermoplasticwastes can be recycled. Recycling of thermosetting
materials is more difficult because of the properties of thesematerials, but they are recycled
as fuel and are used sometimes, by grinding, as fillers in thenew thermosetting materials. For
example, large volumes of tyres from cars, bicycles andtricycles, find application as
materials for calorific utilization .In contrast to siting ofnew landfills or incinerators
facilities, recycling tends to be a politically popularalternatives for the most part. At
industrial scrap level, recycling of plastics grew rapidly afterthe increase in oil prices of the
mid 1970‟s and it now occupies a common place.
Plastic recycling requires information in following threeareas:
Collection and Separation of plastic wastes
Reprocessing technology
Economic viability of the recycled products
In terms of world technology, Europe is the most advanced inrecycling andseparation of different plastics. Despite practicingrecycling within a manufacturing system,
Sl. No. Types of Wastes Mode of Generation
1 Post-Consumer Plastics By the consumers
2 Industrial Plastics Various industrial Sectors
3 Scrap Plastics and fabricator By the plastic compounder
4 Nuisance Plastics Plastic wastes that find
difficult in recycling
8/19/2019 Project on Plastic to Fuel
18/60
Plastic To Fuel Machine ProjectReport2014
18
Japan seems to be devoted to incineration and the use of ash inend products. In the North
America the current incentive for research in these areas isdriven by the rapid reduction of
environmentally safe landfill and expensive systems required forincineration.
The recycling concept of plastics, in effect made its beginningin India in late
sixties. Though earlier on cottage scale, scrap celluloseacetate film and acrylic scrap
continued to find their place in the bangle industry as also forrecovery of monomer. For a
long time, no attempt seem to have been made to record andquantify the plastic wastes,
collected from various sources and get converted into a range ofplastics finished goods; Nor
have there been any attempts to regulate or standardize thequality of recycled materials used.
The recycling metals, papers and glasses are quite advanced inIndia, but the recycling of
plastics is not viable due to the following reasons:
Less quantity of plastic wastes
Limited technology available for recycling ofplastic.
In addition, in other countries, the composition and constituentof the plastic is
explicitly written on the products while in India manufacturershide these information due to
trade secret. This poses problems in the recycling of plastics.The management of plastics
waste could be a major problem, and whether this would beenvironmentally friendly, is
required to be assessed carefully. With the size of our countryand the requirement of plastics
as useful materials for various domestic and industrialapplications, it would not be
appropriate to classify “plastics” as environmental hazards, asthese certainly do not become
a “hazard” even if these go into garbage as wastes or in factdiscarded items. Their collection,
sorting and recycling and reuse and judiciously for identifiedcritical and non-critical
applications with a view to recover the raw materials, areimportant issues that need to be
regulated and coordinated.
2.12. Some Attempts for Plastic Recycling
In most of the situations, plastic waste recycling could also beeconomically
viable, as it generates resources, which are in high demand.Plastic waste recycling also has a
great potential for resource conservation and GHG emissionsreduction, such as producing
diesel fuel from plastic waste. This resource conservation goalis very important for most of
the national and local governments, where rapidindustrialization and economic developmentis putting a lot ofpressure on natural resources. Some of the developed countrieshave
8/19/2019 Project on Plastic to Fuel
19/60
Plastic To Fuel Machine ProjectReport2014
19
already established commercial level resource recovery fromwaste plastics. Therefore,
having a “latecomer‟s advantage,” developing countries can learnfrom these experiences and
technologies available to them.
To raise the awareness and to build the capacity of localstakeholders, UNEP has
started to promote Integrated Solid Waste Management (ISWM)system based on 3R
(reduce, reuse and recycle) principle. This covers all the wastestreams and all the stages of
waste management chain, viz.: source segregation, collection andtransportation, treatment
and material/energy recovery and final disposal. It has beenshown that with appropriate
segregation and recycling system significant quantity of wastecan be diverted from landfills
and converted into resource. Developing and implementing ISWMrequires comprehensive
data on present and anticipated waste situations, supportivepolicy frameworks, knowledgeand capacity to develop plans/systems,proper use of environmentally sound technologies,
and appropriate financial instruments to support itsimplementation. Many national
governments, therefore, have approached UNEP, [as reflected inthe decision taken by the
UNEP Governing Council/Global Ministerial Environment Forumduring its 25 thSession in
February 2009 (UNEP/GC.25/CW/L.3)] to get further support fortheir national and local
efforts in implementation of the Integrated Solid WasteManagement (ISWM) programme.
Plastics are durable and degrade very slowly; the molecular
bonds that make plastic so durable make it equallyresistant to natural processes of
degradation. Since the 1950s, one billion tons of plastic hasbeen discarded and may persist
for hundreds or even thousands of years. In some cases, burningplastic can release toxic
fumes. Burning the plastic polyvinyl chloride (PVC) may createdioxin. Also, the
manufacturing of plastics often creates large quantities ofchemical pollutants. By 1995,
plastic recycling programs were common in the UnitedStates and elsewhere. Thermoplastics
can be remelted and reused, and thermoset plastics can be groundup and used as filler,
though the purity of the material tends to degrade with eachreuse cycle. There are methods
by which plastics can be broken back down to a feedstockstate.
To assist recycling of disposable items, the Plastic BottleInstitute of the Society of the
Plastics Industry devised a now-familiar scheme to mark plasticbottles by plastic type. A
plastic container using this scheme is marked with atriangle of three cyclic arrows, which
encloses a number giving the plastic type:
8/19/2019 Project on Plastic to Fuel
20/60
Plastic To Fuel Machine ProjectReport2014
20
Table 3: Plastic identification code
2.13. Alternative Methods
Unfortunately, recycling plastics has proven difficult. Thebiggest problem
with plastic recycling is that it is difficult to automate thesorting of plastic waste, and so it is
labour intensive. Typically, workers sort the plastic by lookingat the resin identification
code, though common containers like soda bottles can be sortedfrom memory. Other
recyclable materials, such as metals, are easier to processmechanically. However, newmechanical sorting processes are beingutilized to increase plastic recycling capacity and
While containers are usually made from a single type and colourof plastic, making them
relatively easy to sort out, a consumer product like a cellularphone may have many small
parts consisting of over a dozen different types andcolours of plastics. In a case like this, the
resources it would take to separate the plastics far exceedtheir value and the item is
discarded. However, developments are taking place in the fieldof Active Disassembly, which
may result in more consumer product components being re-used orrecycled. Recycling
8/19/2019 Project on Plastic to Fuel
21/60
Plastic To Fuel Machine ProjectReport2014
21
certain types of plastics can be unprofitable, as well. Forexample, polystyrene is rarely
recycled because it is usually not cost effective. Theseun-recycled wastes are typically
disposed of in landfills, incinerated or used to produceelectricity at waste-to-energy plants.
The biggest threat to the conventional plastics industry is mostlikely to be
environmental concerns, including the release of toxicpollutants, greenhouse gas, non-
biodegradable landfill impact as a result of theproduction and disposal of plastics. Of
particular concern has been the recent accumulation ofenormous quantities of plastic trash in
ocean gyres.
Hence we should find a suitable solution for the existence ofthese waste plastics in
our environment. The plastic to fuel machine deals with therecycling of plastics into suitable
form of fuel. For many years, various methods are tried andtested for processing of waste
plastic. The plastic materials are recycled and low valueproducts are prepared. Plastic
materials which cannot be recycled are usually dumped intoundesirable landfill. Worldwide
almost 20% of the waste stream is plastic, most of which stillends up in landfill or at worst it
is incinerated. This is a terrible waste of a valuable resourcecontaining a high level of latent
energy. In recent year this practice has become less and lessdesirable due to opposition from
Government and environmentally conscious community groups. Thevalue of plastics going
to landfill is showing a marginal reduction despite extensivecommunity awareness and
education programs. Research Centre for Fuel Generation (RCFG)has conducted successful
300 successful pilot trials and commercial trials for conversionof waste plastic materials into
high grade industrial fuel. The system uses liquefaction,pyrolysis and the catalytic
breakdown of plastic materials and conversion intoindustrial fuel and gases. The system can
handle the majority of plastic materials that are currentlybeing sent to landfill or which have
a low recycle value. Catalytic conversion of waste plastic intohigh value product is a
superior method of reusing this valuable resource.
The distillate fuel is an excellent fuel and can be used for
1) Diesel electrical generators
2) Diesel burners / stoves
3) Boilers
4) Hot air generators
8/19/2019 Project on Plastic to Fuel
22/60
8/19/2019 Project on Plastic to Fuel
23/60
Plastic To Fuel Machine ProjectReport2014
23
4. Experimental Details
4.1. Principles of the Machine
All plastics are polymers mostly containing carbon and hydrogenand few other
elements like chlorine, nitrogen, etc. Polymers are made up ofsmall molecules, called
monomers, which combine together and form large molecules,called polymers.
When this long chain of polymers breaks at certain points, orwhen lower molecular weight
fractions are formed, this is termed as degradation of polymers.This is reverse of
polymerization or de-polymerization.
If such breaking of long polymeric chain or scission of bondsoccurs randomly, it is
called Random depolymerization. Here the polymer degrades tolower molecular fragments.
In the process of conversion of waste plastics into fuels,random depolymerization is carried
out in a specially designed reactor in the absence of oxygen andin the presence of coal andcertain catalytic additives. The maximumreaction temperature is 350°C. There is total
conversion of waste plastics into value-added fuel products.
4.2. ProcessCarried out in the Machine
4.2.1. Pyrolysis
Pyrolysis is a process of thermal degradation in the absence ofoxygen. Plastic
& Rubber waste is continuously treated in a cylindricalchamber and the pyrolytic gases are
condensed in a specially-designed condenser system. This yieldsa hydrocarbon distillate
comprising straight and branched chain aliphatic, cyclicaliphatic and aromatic hydrocarbons.
The resulting mixture is essentially the equivalent to petroleumdistillate. The plastic / Rubber
is pyrolised at 350-450⁰C and the pyrolysis gases are condensedin a series of condensers to
give a low sulphur content distillate. Pyrolysis is a verypromising and reliable technology for
the chemical recycling of plastic wastes. Countries like UK,USA, and Germany etc have
8/19/2019 Project on Plastic to Fuel
24/60
Plastic To Fuel Machine ProjectReport2014
24
successfully implemented this technology and commercialproduction of monomers using
pyrolysis has already begun there.
Pyrolysis offers a great hope in generating fuel oils, which areheavily priced
now. This reduces the economical burden on developing countries.The capital cost required
to invest on pyrolysis plant is low compared to othertechnologies. So, this technology may
be an initiative to solve fuel crisis and the problems dueto disposal of plastics.
4.2.2. Process
Under controlled reaction conditions, plastics materials undergorandom de-
polymerization and are converted into three products:
a) Solid Fuel i.e., co*keb) Liquid Fuel i.e., Combinationof Gasoline, Kerosene, Diesel and Lube Oil
c) Gaseous Fuel i.e., LPG range gas
The process consists of two steps:
i) Random de-polymerization
- Loading of waste plastics into the reactor along with theCatalyst system.- Random de-polymerization of the wasteplastics.
ii) Fractional Distillation
- Separation of various liquid fuels by virtue of the differencein their boiling points.
One important factor of the quality of the liquid fuel is thatthe sulphur content is less than
0.002ppm which is much lower than the level found in regularfuel.
4.3. Parts of the Machine
4.3.1 REACTOR
Reactor is the major component of this machine. There arecertain critical factors and
they are
Type of feed
Reactor atmosphere
8/19/2019 Project on Plastic to Fuel
25/60
Plastic To Fuel Machine ProjectReport2014
25
Temperature
Pressure
Typical Feedfor the Machine
Table 4: Typical Feed for Machine
Sl.
No.
POLYMER DESCRIPTION As a feed stock
for liquid fuel
1 PE, PP, PS Typical feed stock for
fuel production due to
high heat value and
clean exhaust gas
Allowed
8/19/2019 Project on Plastic to Fuel
26/60
Plastic To Fuel Machine ProjectReport2014
26
2 PET, Phenolic resin ,PVA,
polyoxymethylene
Lower heat value than
above plastics
Not allowed
3 Polyamide,
Polyurethane,Polysulphide
Fuel from this type of
plastics is a hazardous
component such as NOx
and Sox in flue gas.
Not allowed
4 PVC, Poly vinylidenechloride and fluro carbon
polymers.
Source of hazardous andcorrosive flue gas up on
thermal treatment and
combustion
Not allowed
From the table it is very clear that the typical feed in themachine are PE,PP and PS
4.3.2. CATALYTIC CRACKER
Catalytic cracking is the breaking of large hydrocarbonmolecules into smaller and
more useful bits. Catalytic cracker is provided with catalystinside. The cracker must be
designed in such a way that the vapour from the reactor musthave maximum surface contact
with the catalyst. The catalyst will act as a molecular sievewhich permits the passage of
small molecules. There is no single unique reaction happening inthe cracker. The
hydrocarbon molecules are broken up in a fairly random way toproduce mixtures of smaller
hydrocarbons, some of which have carbon-carbon double bonds.
8/19/2019 Project on Plastic to Fuel
27/60
Plastic To Fuel Machine ProjectReport2014
27
4.3.3. CONDENSER
It‟s the part of machine which condenses the vapourscoming out from the catalytic
cracker.
The condenser must condense the very hot vapors in anefficient manner to give the
condensate
Clogging in the condenser must be prevented. This can beachieved by increasing the
diameter of the pipe
In this machine, we are using a spiral condenser to increase theefficiency of
condensation
8/19/2019 Project on Plastic to Fuel
28/60
Plastic To Fuel Machine ProjectReport2014
28
4.3.4. NI TROGEN CYLI NDER
Inert atmosphere in the reactor is provided by pumping nitrogenfrom a nitrogen
cylinder attached to the reactor.
Purpose: plastic feed should not burn instead it should melt athigh temperature inside the reactor.
4.4. Materials Used
Polymers used
Polyethylene (PE)
Polypropylene (PP)
Polystyrene (PS)
8/19/2019 Project on Plastic to Fuel
29/60
Plastic To Fuel Machine ProjectReport2014
29
Catalyst Used
ZSM-5, Zeolite Socony Mobil–5, is analuminosilicatezeolite belonging to the
pentasil family of zeolites. Its chemical formula isNanAlnSi96–nO192·16H2O (0
8/19/2019 Project on Plastic to Fuel
30/60
Plastic To Fuel Machine ProjectReport2014
30
infinity. The structure is orthorhombic (space group Pnma) athigh temperatures, but a phase
transition to
the monoclinic space group P21/n.1.13 occurs on cooling below atransition temperature,
located between 300 and 350 K.
ZSM-5 catalyst was first synthesized by Argauer and Landolt in1972. It is a medium
pore zeolite with channels defined by ten-membered rings.The synthesis involves three
different solutions. The first solution is the source ofalumina, sodium ions, and hydroxide
ions; in the presence of excess base the alumina will formsoluble Al(OH)4–ions. The second
solution has the tetrapropylammoniumcation that acts as atemplating agent. The third
solution is the source of silica, one of the basic buildingblocks for the framework structure of
a zeolite. Mixing the three solutions produces supersaturatedtetrapropylammonium ZSM-5,
which can be heated to recrystallize and produce asolid.
4.5.Laboratory Set Up30g of weighed plastic granules arefed into the round bottom flask. The round bottom flask
is provided with a continuous supply of inert nitrogen gas usinga nitrogen gas cylinder. Heat
is provided by using Bunsen burner which may be between350-450⁰C. It is the temperature
at which plastic begins to melt and vaporise. The vapours arepassed through the catalyst
which is kept at a certain temperature. The vapours are thencondensed using a condenser
attached to round bottom flask. At the end of condenser, thedistillate is collected. The
amount of distillate obtained is measured. The colour of thedistillate is noted. The time andtemperature at which thedistillate is obtained is also noted. 1ml of distillate is taken ina
china dish and it is ignited. It burns and the time taken forignition is noted. The experiment is
repeated with different plastics such as LDPE, HDPE, PP, PS,plastic wastes (mainly plastic
carry bags, CD case etc.)
8/19/2019 Project on Plastic to Fuel
31/60
Plastic To Fuel Machine ProjectReport2014
31
4.6. Process to be carried out:
Pretreatment of plastics. i.e. removal of water andimpurities
Loading of treated plastic into fluidized bed reactorprovided with refractory bricks.
Heating the materials to 350-450 degree Celsius in aninert atmosphere.
Inert atmosphere is provided by a nitrogen cylinderconnected to the reactor.
Carrying the vapours to a catalytic chamber provided withsuitable catalyst
Purpose of catalyst is to crack long chain hydrocarbons intosmall chain
molecules. it is also involved the isomerisation of themolecules.ie, linear
hydrocarbon chain changed into branched because the branchedones have higher
octane number which is the major component of the fuel.
8/19/2019 Project on Plastic to Fuel
32/60
Plastic To Fuel Machine ProjectReport2014
32
Designing of the catalytic cracker in such a way that itshould provide maximum
surface contact of the vapours with the catalyst.
Plastics that has been cut into coarse granules is fed into atrough. It then moves through
various tubes and chambers. Through the process, the plastic isheated into a liquid and then
into a gas, and then cooled. At the end, a light coloured oildrips from a spigot into a
receptable (The machine can process about 10kg of plastic andproduce about 10 litres of oil
every hour and can run continuously around the clock). The onlyother by-products include a
tiny bit of carbon residue, CO2 and water vapour.
Just about any plastic can be fed into the machine. Paperlabels and a little dirt won‟t
hurt it, but the material should be relatively dry. The oil thatcomes out is a blend of gasoline,
diesel, kerosene and some heavy oils. It can be fed directlyinto an oil furnace or could be
processed further into something that could go straightinto a diesel car.
4.7.Inferences Drawn From Experiment
Polystyrene (PS) is a solvent for rubber ( It dissolved therubber tube used for theexperiment)
Mainly polyethylene (PE), polypropylene (PP), polystyrene(PS) only gives such
distillate
Plastic waste gives only less amount of distillate thanpure polymer granules (since it
contains other additives in it)
In case of polystyrene (PS), more smoky fumes areproduced due to its structural
properties arising due to its aromatic structureBecause the entire process takes place inside vacuum and theplastic is melted and not
burned, minimal to no toxins are released in to theair
Burning pure hydrocarbons such as PE and PP will producea fuel that burns fairly
clean
While burning PVC large amounts of chlorine will corrodethe reactor and pollute the
environment
8/19/2019 Project on Plastic to Fuel
33/60
Plastic To Fuel Machine ProjectReport2014
33
Different tests have been carried out to study and compare thefuel characteristics of different
samples and those of petrol and diesel which are used as thestandard reference. The
characteristics which are studied are:
5. Test for Characterizing Output
5.1. Calorific Value
It is the amount of heat produced by the complete combustion offuel. It is measured in
units of energy per amount of material.eg: kJ /kg
Instrument used : Bomb Calorimeter
5.1.1 Principle:
8/19/2019 Project on Plastic to Fuel
34/60
Plastic To Fuel Machine ProjectReport2014
34
A weighed sample of the fuel is burned in oxygen in a bombcalorimeter under
controlled conditions. The calorific value is calculated fromthe weight of the sample and the
rise in temperature of the water.
1. Stand with illuminators and magnifiers
2. Thermometer
3. Motor
4. Stirrer
5. Lid
6. Outer jacket
7.
Calorimeter vessel8. Bomb assembly
9. Electrical connecting leads
10.Schrader valve
11.Ignition wire
12.Crucible
13.Water
14.
Firing unit
5.1.2. Procedure
Weigh a suitable quantity of sample of fuel whose calorificvalue is to be found out,
in a stainless steel oil cup to the nearest 0.1 mg. For solidfuels make a pellet of the fuel and
weigh it to the nearest 0.1 mg. Place the pellet in the crucibleinside the bomb.
Place the oil cup in the circular ring attached to the terminalsof the bomb for liquid fuels.
Attach a length of nichrome wire across the bomb terminals.Weigh a suitable length of dry
cotton or a strip of filter paper, and tie or support it as thecase requires, at the centre of
nichrome wire, so that its free end dips into the contents ofthe oil cup
Admit oxygen from the cylinder slowly, so that the oil is notblown from the cup until the
appropriate pressure is reached. For aviation and motor fuels,this pressure must lie between
25 and 30atm and for kerosene and heavier fuels between 25 and27 atm.
8/19/2019 Project on Plastic to Fuel
35/60
Plastic To Fuel Machine ProjectReport2014
35
The calorimeter vessel is filled with water such that the coverof the bomb will be submerged
within it when placed in position.
Place the prepared bomb with electrical leads, in the water inthe calorimeter. Check that
there is no leakage of oxygen. Confirm that the firing leads aredead, and make the
appropriate connections. Put the cover in position, arrange thethermometer and stirrer in
position so that they do not touch the bomb or the vessel,and start the stirrer (driven by a
small induction motor).
The temperature of water is noted. Fire the charge by closingthe firing circuit for two
seconds. Find out the maximum temperature attained by the waterin the calorimeter.
Make sure that all the oil has burned.
5.1.3. Calculations
Mass of the sample burned = m grams
Initial water temperature = TioC
Final water temperature = Tf0C
Water equivalent of calorimeter, mw = 2350 gms
Specific heat of water , Cw = 4.187 J/gm/k
Let CV be the calorific value of the fuel burned. Then the heatof burning of fuel=
heat given to the calorimeter and water.
i.e. mCV = mwCw[Tf-Ti]
CV = mwCw[Tf-Ti]/m
Heat due to the burning of cotton strip is not taken intoaccount.
8/19/2019 Project on Plastic to Fuel
36/60
Plastic To Fuel Machine ProjectReport2014
36
5.2. Viscosity
It is defined as measure of the resistance to gradualdeformation by shear or tensile
stress.
For liquids, it refers to „thickness‟.
Unit is centipoise (cp)
Instrument used : Cone and Plate Viscometer
Viscosity is the measure of the internal friction of a fluid.This friction becomes apparent
when a layer of fluid is made to move in relation to anotherlayer. The greater the friction, the
greater the amount of force required to cause this movement,which is called shear. Shearing
occurs whenever the fluid is physically moved or distributed asin pouring, spreading,
spraying, mixing etc. Highly viscous fluids therefore requiremore force to move than less
viscous materials. Sir Isaac Newton postulated that, forstraight, parallel, and uniform flow,
the shear stress τ between layers is proportional to thevelocity gradient, du/dy, in the
direction perpendicular to the layers.
τ = η du
dy
8/19/2019 Project on Plastic to Fuel
37/60
Plastic To Fuel Machine ProjectReport2014
37
Here the constant η is known as the coefficient of viscosity,the viscosity, the dynamic
viscosity or the Newtonian viscosity. The velocity gradientdu/dy is a measure of the change
in speed at which the intermediate layers move with respect toeach other and it describes the
shearing of the liquids, often referred as shear rate with unitas sec inverse the force per unit
area required top produce the shearing, is the shear stress (τ)and is expressed as dynes/cm2.
Thus, viscosity can be defined mathematically as
Poise= τ
dudy
The absolute viscosity of samples under conditions of definedshear rate and shear
stress were determined by a programmable Brookfield DV-II + coneand plate viscometer
thermo stated in the temperature range 25-60+-1C. Its cone andplate spindle geometry
requires a sample volume of only 0.5 to 2ml and generates shearrates in the range of 0.6 to
1500 reciprocal seconds.
The Brookfield DV-II+ cone and plate viscometer is of therotational variety. It
requires the torque that is needed to rotate an immersed element(the spindle) in a fluid. The
spindle is driven by a synchronous motor through a calibratedspring; the deflection of the
spring is indicated by a digital display. By using a multiplespeed transmission and
interchangeable spindles a variety of viscosity ranges can bemeasured. For a given viscosity,
the viscous drag or resistance to flow is proportional to thespindle‟s speed of rotation and is
related to the spindle‟s size and shape (geometry).the drag willincrease as the spindle s ize
and /or rotational speed increases. It follows that for a givenspindle geometry and speed, an
increase in viscosity will be indicated by an increase in thedeflection of the spring.
5.3. Acidity (Acid value)
5.3.1. Definition:
It is the mass of potassium hydroxide in milligrams that isrequired to neutralize 1g of
chemical substance
8/19/2019 Project on Plastic to Fuel
38/60
Plastic To Fuel Machine ProjectReport2014
38
5.3.2. Procedure:
Known amount of sample dissolved in organic solvent is titratedwith a solution of
KOH with known concentration and with phenolphthalein as a colorindicator
2×0.56 g of KOH is dissolved in 200 ml of distilled water. Takethis in a burette (50 ml). 1 g
of oil is added to 50 ml of methanol. Heat it at 400C (put amagnetic stirrer). Add two drops
of phenolphthalein as colour indicator. Titrate against 0.1 MKOH. The end point value is
noted.
Acidity = 2 X 0.56/V
5.4. Density and Specific Gravity
Density is defined as mass per unit volume. Its unit isg/cm³
Specific gravity is defined as the ratio of density of asubstance to the
density of a reference standard. Here, water is used asreference standard.
Instrument used : Density bottle
It is made of glass, consists of a closely fitting stopper and acapillary tube inside it.
8/19/2019 Project on Plastic to Fuel
39/60
Plastic To Fuel Machine ProjectReport2014
39
A pycnometeralso called specific gravity bottle, is adevice used to determinethe density of a liquid. A pycnometer isusually made of glass, with a close-fitting ground
glass stopper with a capillary tube through it, so that airbubbles may escape from the
apparatus. This device enables a liquid's density to be measuredaccurately by reference to an
appropriate working fluid, such as water or mercury, using ananalytical balance.
If the flask is weighed empty, full of water, and full of aliquid whose relative density is
desired, the relative density of the liquid can easily becalculated. The particle density of a
powder, to which the usual method of weighing cannot beapplied, can also be determined
with a pycnometer. The powder is added to the pycnometer, whichis then weighed, giving
the weight of the powder sample. The pycnometer is then filledwith a liquid of known
density, in which the powder is completely insoluble. The weightof the displaced liquid can
then be determined, and hence the relative density or specificgravity of the powder.
8/19/2019 Project on Plastic to Fuel
40/60
Plastic To Fuel Machine ProjectReport2014
40
6. RESULTS AND DISCUSSIONS
6.1. Test Results
6.1.1. Calorific value
SAMPLE CALORIFIC VALUE (kJ/kg)
PE 42829.65
PP 42145.91
PS 37881.08
PE
(catalyst)
43817.97
PP
(catalyst)
33866.58
PS
(catalyst)
38519.28
PE
WASTE
40252.30
PP
WASTE
37166.63
PS
WASTE
37344.74
Petrol 44400
diesel 43200
8/19/2019 Project on Plastic to Fuel
41/60
Plastic To Fuel Machine ProjectReport2014
41
Calorific value vs. Polymer sample
X-axis: polymer sample Y-axis: calorific value
From the table and the graph, it can be concluded that calorificvalue of the
sample fuel is comparable to that of the reference petrol anddiesel. Also, the calorific valueis increased on using the catalystand the calorific value of the plastic waste is less than the
pure sample since it contains many other additives.
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst
8/19/2019 Project on Plastic to Fuel
42/60
Plastic To Fuel Machine ProjectReport2014
42
6.1.2. Viscosity
SAMPLE VISCOSITY (cp)
PE 1.92
PP 1.15
PS 1.31
PE
(catalyst)
1.39
PP
(catalyst)
.82
PS
(catalyst)
0.89
PE
WASTE
.64
PP
WASTE
.41
PS
WASTE
.44
Petrol .33
diesel 3.22
8/19/2019 Project on Plastic to Fuel
43/60
Plastic To Fuel Machine ProjectReport2014
43
Viscosity vs. Polymer sample
X-axis: polymer sample Y-axis: Viscosity
From the table and graph, it can be concluded that the viscosityis reduced on using
the catalyst and it is comparable to that of petrol and diesel.The relevance of the catalyst is
also very much understood from this test. The catalyst acts as amolecular sieve hence only
small hydrocarbon molecules are present in the output thereforetheir viscosity will be less
compared to samples without catalyst.
0.5
1
1.5
2
2.5
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst
8/19/2019 Project on Plastic to Fuel
44/60
Plastic To Fuel Machine ProjectReport2014
44
6.1.3. Acidity
ACIDITY (in pH)
PE 2.26
PP 2.51
PS 2.06
PE
(catalyst)
1.13
PP
(catalyst)
1.243
PS
(catalyst)
2.26
PE
WASTE
1.384
PP
WASTE
1.299
PS
WASTE
1.424
Petrol 1.02
diesel 1.01
8/19/2019 Project on Plastic to Fuel
45/60
Plastic To Fuel Machine ProjectReport2014
45
Acidity vs. Polymer sample
X-axis: polymer sample Y-axis: acidity
From the table and graph, it can be concluded that acidity ofthe samples is
closely approaching to the values of petrol and diesel and thevalues are reduced on using the
catalyst.
0.5
1
1.5
2
2.5
3
PE PP PS
pure sample
pure sample
with catalyst
plastic waste
with catalyst
8/19/2019 Project on Plastic to Fuel
46/60
Plastic To Fuel Machine ProjectReport2014
46
6.1.4. Density and Specific Gravity
Density
(g/cm³)
Specific
gravity
PE 1.151 1.151
PP 1.143 1.143
PS 1.359 1.359
PE(catalyst)
1.023 1.023
PP
(catalyst)
1.118 1.118
PS
(catalyst)
1.179 1.179
PE
WASTE
1.112 1.112
PP
WASTE
1.111 1.111
PS
WASTE
1.321 1.321
Petrol 1.063
Diesel 1.211
8/19/2019 Project on Plastic to Fuel
47/60
Plastic To Fuel Machine ProjectReport2014
47
Density vs. Polymer sample
X-axis: polymer sample Y-axis: density
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst
8/19/2019 Project on Plastic to Fuel
48/60
Plastic To Fuel Machine ProjectReport2014
48
Specific gravity vs. Polymer sample
X-axis: Polmer Sample Y-axis: specific gravity
From the table and graph, it can be concluded that both densityand specific gravity of
the samples are closely approaching the values of the standardreference petrol and diesel.
Also, the values are increased on using the catalyst.
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst
8/19/2019 Project on Plastic to Fuel
49/60
Plastic To Fuel Machine ProjectReport2014
49
6.2. Role of Catalyst in the Process
Here the catalyst used is HZSM-5. The optimization of wasteplastic as a function
of temperature in a batch mode reactor gave liquid yields ofabout 80% at a furnace
temperatures of about 600 degrees centigrade and one hrresidence time. Sodium carbonate or
lime addition to the pyrolysis and co-processing reactorsresults into an effective chlorine
capture and the chlorine content of pyrolysis oil reduces toabout 50-200ppm. The volatile
product from this process is scrubbed and condensedyielding about 10-15%gas and 75-80%
of a relatively heavy oil product.
The catalyst is a molecular sieve which will permit only thepassage of smallhydrocarbon molecules through them. The relevanceof catalyst is that, the desirable final
product is mixed oil that consists of gasoline, diesel oiland kerosene. In the absence of
molecular sieve (catalyst), the final product consists of largehydrocarbon chains which get
polymerized when brought into normal conditions. Thepresence of small chain hydrocarbons
in the product is achieved by the use of catalyst.
% Conversion Vs Catalyst
Figure: Comparison of HZSM--5 catalyst with other catalystsbased on its performance
From figure , it is very clear that the performance of thecatalyst HZSM-5 is very high compared to all
other catalysts. This is the reason why we use this particularcatalyst in our machine.
8/19/2019 Project on Plastic to Fuel
50/60
Plastic To Fuel Machine ProjectReport2014
50
6.3. Molecular Structure of the Catalyst
Figure: Molecular Structure of the Catalyst
From the figure, it is very clear that the catalyst is amolecular sieve which permits only the
passage of small hydrocarbon molecules through them.
ZSM-5, Zeolite Socony Mobil–5, isanaluminosilicatezeolite belonging to
the pentasil family of zeolites. Its chemical formula is NanAlnSi96–nO192·16H2O (0
8/19/2019 Project on Plastic to Fuel
51/60
Plastic To Fuel Machine ProjectReport2014
51
6.4. Process taking place in a Catalytic Reactor:
Pictorial Representation:
6.5. Features of Catalyst to be used:
Catalyst which is more selective to octanes
The octane is one of the molecule found in petrol. Hydrocarbonsused in petrol(gasoline) are given an octaneratingwhich relates to how effectively they performin
8/19/2019 Project on Plastic to Fuel
52/60
Plastic To Fuel Machine ProjectReport2014
52
the engine. A hydrocarbon with a high octane rating burns moresmoothly than one
with a low octane rating
Catalyst which possess limited deactivation by co*ke
co*ke is deposited on catalyst when vapors passes through themwhich may cause
catalyst deactivation
Catalyst which possess high thermal stability
Vapors at high temperature is passing through the catalyst whichwill affect its
stability
6.6. Cracking of Molecules in Reactor in Presence ofCatalyst
Table: Cracking of Molecules in Reactor in Presence ofCatalyst
8/19/2019 Project on Plastic to Fuel
53/60
Plastic To Fuel Machine ProjectReport2014
53
The figure shows the breaking of different hydrocarbon chains inthe reactor in the presence
of the catalyst.
6.7. Regeneration of catalyst:
co*ke will be deposited on catalyst during the process. But thiscatalyst can be regenerated by
burning. Hence, co*ke deposited is removed.
6.8. Need of Catalytic Cracking:
The final product we get is mixed oil that consists of gasoline,diesel
oil, kerosene. In absence of the molecular sieve(catalyst) , thefinal product consist of large
hydrocarbon chains which get polymerized when brought intonormal conditions hence we
need to break or permit only the presence of small chainhydrocarbons in the product. This is
achieved by the catalytic cracker.
8/19/2019 Project on Plastic to Fuel
54/60
Plastic To Fuel Machine ProjectReport2014
54
7. Conclusion
Cost for the fuel is increasing day by day and also the problemarising
due to the improper waste disposal of plastics are increasing inour country.
This plastic to fuel machine can solve both these problem in themost efficient
manner. This process offer many advantages such as:
1) Problem of disposal of waste plastic is solved.
2) Waste plastic is converted into high value fuels.
3) Environmental pollution is controlled.
4) Industrial and automobile fuel requirement shall be fulfilledto some extent at lower
price.
5) No pollutants are created during cracking of plastics.
6) The crude oil and the gas can be used for generation ofelectricity.
We have carried out the process with and without catalyst andthe test results have improved
by using the catalyst:
Calorific value increased
Acid value decreased
Viscosity decreased
Density and specific gravity decreased
Lastly, further studies are required in future for economicimprovementand its
design flexibility.
8/19/2019 Project on Plastic to Fuel
55/60
Plastic To Fuel Machine ProjectReport2014
55
8. References
Converting Waste Plastics into a Resource,Compendium ofTechnologies
Compiled by
United Nations Environmental Programme
Division of Technology, Industry and Economics
International Environmental Technology Centre
Osaka/Shiga, Japan
Thermal Decomposition of Polymers
Craig L. Beyler and Marcelo Hirschler
Handbook of Fluidization andFluid–Particle Systems
Edited by
Wen- Ching Yang (Siemens Westinghouse Power Corporation
Pittsburgh, Pennsylvania, U.S.A. MARCEL.
Sustainable Plastics - website promoting bioplastics:
www.sustainableplastics.org/
US Energy Information Association: Crude Oil facts
FAQs:www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plastics
ChemTrust–information on Chemicals andHealth:www.chemtrust.org.uk/
Plastics Industry Perspective on the health impacts fromPVC:
www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditives
Polymer degradation to fuels over micro-porous catalystsas a novel tertiary
plastic recycling method, Polymer Degradation and
Stability
http://www.sustainableplastics.org/http://www.sustainableplastics.org/http://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.chemtrust.org.uk/http://www.chemtrust.org.uk/http://www.chemtrust.org.uk/http://www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditiveshttp://www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditiveshttp://www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditiveshttp://www.chemtrust.org.uk/http://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.sustainableplastics.org/
8/19/2019 Project on Plastic to Fuel
56/60
Plastic To Fuel Machine ProjectReport2014
56
KarishmaGobin, George Manos
Thermal degradation of municipal plastic waste forproduction of fuel-like
hydrocarbons, Polymer Degradation and Stability
N. Miskolczia, L. Barthaa, G. Dea´ka, B. Jo´ verb
8/19/2019 Project on Plastic to Fuel
57/60
Plastic To Fuel Machine ProjectReport2014
57
Certifications
8/19/2019 Project on Plastic to Fuel
58/60
Plastic To Fuel Machine ProjectReport2014
58
8/19/2019 Project on Plastic to Fuel
59/60
Plastic To Fuel Machine ProjectReport2014
59
8/19/2019 Project on Plastic to Fuel
60/60
Plastic To Fuel Machine ProjectReport2014
FAQs
How can we convert plastic into fuel? ›
Through pyrolysis, the plastic is heated to extremely high temperatures, between 300⁰C and 900⁰C, with a lack of oxygen. This causes it to break down into smaller molecules and transforming it into pyrolysis oil or gas.
What fuel can be made from plastic? ›Scientists in the world are doing research and experiments and they succeeded in turning plastic waste into Diesel by method depolymerization. By this method, LDPE plastics can be depolymerized into high-grade fuel i.e Diesel.
What is the technology used to convert plastic to fuel? ›As the plastic waste is heated, it undergoes a chemical transformation called Catalytic Thermo Liquefaction (CTL). This process converts the plastic waste into a substance called Hydrocarbon Oil (HC-Oil). The resulting HC-Oil is a type of fuel that can be used for various purposes.
Is plastic to fuel profitable? ›The market for plastic-to-fuel in the United States is predicted to have a profitable development potential due to the rising demand for plastic-to-fuel machines.
Why can't we turn plastic into fuel? ›The strong carbon–carbon bonds in these plastics requires very high temperatures to break, making the process energy intensive. Once the bonds break, the smaller molecules that are created quickly form new bonds, giving unwanted compounds. These byproducts then have to be broken down again, adding time and complexity.
What company is turning plastic into fuel? ›Plastic2Oil® is a clean energy company that recycles waste plastic into liquid fuels, providing economic and environmental benefits.
Which fuels make 99% of all plastics? ›That's because 99% of all plastics are manufactured from fossil fuels—oil, gas, and coal—which emit greenhouse gases from cradle to grave.
What plastic is best for fuel? ›Benefits Of Petrochemical Plastics For Gas & Oil Storage
A sturdy plastic like high-density polyethylene (HDPE) is commonly used to make plastic gas cans and barrels because it insulates its contents, and shields gas from the heat of its environment.
Gasoline should only be stored in containers that are specifically manufactured for gasoline storage, like our Type I Safety Cans and Type II Safety Cans. Gas containers can be made of plastic or metal, but are always fortified with safety features.
What is the machine converting plastic to fuel? ›Waste plastic pyrolysis machine is used for recycling plastic to fuel. This machine utilizes the process of pyrolysis, which involves the thermal decomposition of plastic waste in the absence of oxygen to produce useful products like fuel oil. The obtained fuel oil has multiple applications.
Who invented plastic to fuel? ›
Jayme Navarro, a Filipino inventor from the town of Bacolod, has found a useful method to turn plastic trash into usable fuel, such as gasoline, diesel, and kerosene. Navarro made this discovery while trying to convert plastic waste, such as plastic bottles, bags, utensils, and such back into their original form.
What catalyst is plastic to fuel? ›Ali et al., [163] did pyrolysis on waste plastic to produce jet fuel with graphite as an activated carbon catalyst. They discovered a strong relationship between products and temperature when waste plastics were heated in an inert atmosphere reactor at 350–450 °C.
What are the disadvantages of turning plastic into fuel? ›The low calorific value and high viscosity of the waste plastic fuel are the two most significant drawbacks of utilizing plastic fuel as a diesel engine.
Why is pyrolysis bad? ›Gasification and Pyrolysis: Incineration by Different Names
With limited oxygen and high heat, these facilities generate synthetic gases and oils, along with ash, char, and air pollution. They are dangerous to our health and to our environment.
Furthermore, it is also important to understand that pyrolysis of plastic waste eventually turns the polymers back into hydrocarbons; some of them such as aromatic compounds are dangerous substances and are classified as possible carcinogens.
Can we turn plastic back into oil? ›Plastic to Crude Oil. Plastics have successfully ben converted to crude oil via pyrolysis of high-density polyethylene bags. The plastic crude oil produced can be refined via fractional distillation to produce gasoline and two different types of diesel [39].
Is pyrolysis bad for the environment? ›However, the pyrolysis process also has a significant environmental impact, mainly due to gas emissions. It is important to quantify this environmental impact and compare it with alternative treatment methods to identify the best management strategy for contaminated mixed plastic waste.
How can we turn waste into fuel? ›Yes, you can turn waste into energy through incineration, anaerobic digestion, gasification, and pyrolysis, among other processes. WTE technology can convert trash into green electricity, heat, or biogas, contributing to an efficient waste management system and reducing landfill volumes.