Detailed Project Report on pyrolysis oil from plastic waste

PYROLYSIS OIL FROM PLASTIC WASTE

[CODE NO4124] 

The disposal of plastic waste and used tyre by land filling is becoming an increasingly serious problem from a environmental and economic stand point, a better solution is to reprocess tire into valuable products such as activated carbon other solid carbon form (e.g. carbon black) and liquid and gaseous fuel.

A process design is proposed which involves pyrolysis of plastic waste and used tires, activation of the solid residue, partial combustion of liquid to produce carbon black and the use of high BTU gas for process heat. The activation of the solid residue is done using CO2 which produces CO and activated carbon.

The CO2 is regenerated and the lost carbon is recovered using the boudouard reaction to produce CO2 and finely divided carbons. The latter material may be used as a substitute for carbon black.

For many years, various methods are tried and tested for processing of waste plastic. The plastic materials are recycled and low value products are prepared. Plastic materials which cannot be recycled are usually dumped into undesirable landfill.

Worldwide almost 20% of the waste stream is plastic, most of which still ends up in landfill or at worst it is incinerated. This is a terrible waste of a valuable resource containing a high level of latent energy.

In recent year this practice has become less and less desirable due to opposition from Government and environmentally conscious community groups. The value of plastics going to landfill is showing a marginal reduction despite extensive community awareness and education programs.

Research Centre for Fuel Generation (RCFG) has conducted successful 300 successful pilot trials and commercial trials for conversion of waste plastic materials into high grade industrial fuel. The system uses liquefaction, pyrolysis and the catalytic breakdown of plastic materials and conversion into industrial fuel and gases. The system can handle the majority of plastic materials that are currently being sent to landfill or which have a low recycle value.

Catalytic conversion of waste plastic into high 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

5) Hot water generators

6) Diesel pumps

The distillate can be further fractionated into fuels as under and can be used in automobiles.

1) Petrol

2) Kerosene

3) Diesel

Crude oil, Petroleum Gases and Activated Carbon are the product of waste plastic.

The term Activated carbon, active carbon, or active charcoal is usually applied to amorphous carbons possessing higher absorption capacities than wood or animal charcoal. Many processes were developed during world war for the production of effective absorbents for use in gas masks. Industrial activated carbons in the form of pellets, granules or fine powders, and with many industrial applications, are now available in the market under different trade names.

Commercial absorbent carbons may be grouped into decolorizing, gas absorbent, metal absorbent, and medicinal carbons according to their physical structure, properties and applications. No one type of carbon can be used for all purposes. A large variety of raw materials are available for the manufacture of these products. Coal, petroleum coke and wood charcoal are activated by gas activation. Industrial waste e.g. raw dust, begasse, molasses, straw, coconut pericarp and shell, corn cobs, paddy and ground nut husk, corn bean shell, distillery slop, waste Mahua flowers, waste wood pulp laquor and mud from sugar factories have been utilized for the production of active carbons by chemical activation.

DECOLORISING CARBONS

Decolorising carbons are manufactured by gas activation, in which the raw materials are first carbonized and the resulting charcoal heated to a high temperature in an oxidizing atmosphere Chemical activation in which the raw materials are impregnated with a chemical extruded and carbonized and deposition of carbon on porous inorganic base activation is needed in this case.

In the gas activation process, the raw material is carbonized under controlled conditions in closed retorts, the resulting charcoal is crushed, screened and heated in a second retort at 1000oC for 10 to 12 hours in an atmosphere of air, carbon dioxide, chlorine, super heated steam or a mixture of steam and air. Raw materials which do not possess the necessary density and structure for direct conversion are briquetted prior to carbonization. Prebriquetting gives a higher yield and a better product. In the process for the direct conversion of coal to activated carbon the crushed-materials, screened to 11/8 in pieces, is carbonized at 450o - 500oC and steam activated at 950o in continuous vertical retorts, the yield is about 12 1/2% of the coal taken.

For activation by chemical treatment, the raw material is ground and formed into paste with chemicals, e.g. chloride of zinc, calcium and magnesium, alkalies, sulphuric acid, phosphoric acid, sodium, silicate, boric acid, potassium sulphide, lime, ferric chloride, or potassium thiocynate. The paste is extruded under pressure dried and carbonized in gas retorts at about 1000oC. The charcoal is cooled, washed with hydrochloric acid and water to remove inorganic residues and finally dried at about 300oC. A fluidization technique has been developed in France for the production of activated carbon.

The third process gives a product with a porous structure and appreciable mechanical strength. The raw materials viz saw dust, sea weed, peat molasses etc. is mixed with a insoluble salts and the mixture is strongly heated. The carbon gets deposited on the porous inorgenic base. A similar product is obtained when a high ash vegetable product, such as paddy husk, containing an appreciable percentage of silica is carbonized.

GAS ABSORBENT CARBONS

Gas and vapour absorbent carbons are obtained by carbonizing coconut shells, apricot stones, vegetable ivory and anthracit. In recent years, methods have been developed for using softer materials which are rendered hard and dense by briquetting. The carbons are gas activated. A preparation useful for gas masks has been obtained by chlorinate bituminous coal (6-20) mesh until a 100% increased in weight takes place, pelleting and chlorinated material with hydrolyzed starch as binder, baking, crushed and powdered to (8-20) mesh and steam activated at 800oC. Gas absorbent carbons are available in granular form of specified mesh range, e.g. 4 x 6, 412, 20, i.e. retained on 6- and 20 mesh sieve and passing through 4.12 mesh sieve.

METAL ABSORBENT CHARS

Metal absorbent chars are prepared by alkali activation. Structurally, they are identical with decolorizing carbons and are converted into the lather by acid treatment. An active product is obtained by heating bone charcoal with alkali at 850oC. The product obtained is negative changed material and important of its metal absorbing power. It however, possesses the properties of a decolorizing char. Treatment of flocculated material with alkali does not restore the metal absorbent properly.

MEDICINAL CARBONS

Activated carbon finds application in the preparation of pills and digestive tablets. Its absorptive properties are utilized in the treatment of the stomach due to hyper acidity. It removes toxic amines, organic acids of decomposed foods and probably also bacteria from the intestinal tract and many other purposes.

COST ESTIMATION

Plant Capacity            3000 Ltr./Day  

Land & Building (20,000 sq.ft.)  Rs. 37 Lac    

Plant & Machinery                    Rs. 1.17Cr 

Working Capital for 1 Month    Rs. 25 Lac

Total Capital Investment          Rs. 1.88Cr 

Rate of Return                          22%

Break Even Point                      74%

INTRODUCTION

THE DISTILLATE FUEL IS AN EXCELLENT FUEL AND CAN BE USED FOR

THE DISTILLATE CAN BE FURTHER FRACTIONATED INTO FUELS AS 

   UNDER AND CAN BE USED IN AUTOMOBILES.

DECOLORISING CARBONS

GAS ABSORBENT CARBONS

METAL ABSORBENT CHARS

MEDICINAL CARBONS

USES AND APPLICATION OF CRUDE OIL/INDUSTRIAL FUEL

DIESEL ENGINES

FILTERED CRUDE OIL CAN BE USED IN:

TYPICAL INDUSTRIAL APPLICATION FOR THE EXPLOITATION OF PYRO 

    FUEL AS THE FUEL

RAW MATERIALS

LICENSES FOR MANUFACTURE, STORAGE AND SALE

STANDARD OF FUEL

CLASSIFICATION OF PYROLYSIS

TABLE 1. TYPICAL OPERATING PARAMETERS AND PRODUCTS FOR 

    PYROLYSIS PROCESS

SLOW PYROLYSIS

FAST PYROLYSIS

FLASH PYROLYSIS

MARKET OVERVIEW OF PYROLYSIS OIL

SOME OF THE PROMINENT PLAYERS IN THE PLASTIC TO FUEL 

    MARKET INCLUDE:

PYROLYSIS OIL FROM PLASTIC WASTE

REACTOR:-

GAS RECEIVER:

CATALYTIC TOWER:

ANTI FLASHBACK DEVICE:

MODE OF HEATING:

STORAGE TANK:

SCRUBBER:

CHIMNEY:

FLARING SYSTEM:

CONTROL PANEL:

ENVIRONMENT FRIENDLY PROCESS:

ADVANTAGES OF PYROLYSIS OF PLASTIC/TYRE WASTE POLLUTION

PROPERTIES OF PETRO ALTERNATE FUEL (PAF)

PYROLYSIS PROCESS DESCRIPTION

BIOMASS HEATING

TABLE: TYPICAL HEATING METHODS USED IN DIFFERENT REACTORS.

CHAR SEPARATION

LIQUIDS COLLECTION

PYROLYSIS PRODUCTS

TABLE: PYROLYSIS REACTIONS AT DIFFERENT TEMPERATURES.

PYROLYSIS BIO-OIL

TABLE: PHYSICAL PROPERTIES AND CHARACTERISTICS OF 

    PYROLYSIS BIO-OIL.

TABLE: PROPERTIES NO.2 DIESEL FUEL AND PYROLYSIS BIO-OIL 

    FROM DIFFERENT FEED STOCKS.

TABLE: ELEMENTARY ANALYSIS OF NO 2 DIESEL, COAL AND PYROLYSIS 

    BIO-OIL FROM DIFFERENT FEED STOCKS.

FIGURE: VARIOUS APPLICATIONS OF PYROLYSIS BIO-OIL.

DEPOLYMERIZATION TECHNOLOGY

THERMOCHEMICAL DECOMPOSITION OF THE PLASTIC OR TIRE POLYMER

BENEFIT OF LOW TEMPERATURE CATALYTIC DEPOLYMERIZATION 

    OF PLASTIC OIL AND TIRES

TECHNOLOGY, PROCESS AND ADVANTAGE OF PYROLYSIS

ADVANTAGES OF THE MANUFACTURING PROCESS:

PROCESS OF CONVERSION WASTE PLASTIC WITH TYRES INTO 

   ACTIVATED CARBON AND INDUSTRIAL FUEL

METHOD FOR CHAR ACTIVATION

PROCESS FLOW DIAGRAM

PROCESS DESCRIPTION IN DETAILS

FEED STREAM PREPARATION:-

PYROLYSIS AND CHAR-ACTIVATION UNITS:-

CARBON-BLACK PRODUCTION:-

BOUDOUARD CARBON PRODUCTION FROM CO:-

THE ENERGY BALANCE:-

METHOD F WASTE TREATMENT TO FUEL AND CHEMICAL USING    

      PYROLYSIS

MANUFACTURING OF ACTIVATED CARBON

FUELS AND CHEMICALS FROM POLYMER WASTES

FIG. 2: SCHEMATIC OF THE FLOW PYROLYSIS LABORATORY EQUIPMENT

FIG. 3: SCHEMATIC DIAGRAM OF THE THERMAL DECOMPOSITION  

      REACTOR

FUELS AND CHEMICALS FROM USED TYRES

FIG. 4: THE DESIGN OF THE PILOT PLANT REACTOR

FIG. 5: THE VIEW OF THE TECHNOLOGICAL UNIT IN MLIEČANY

ADVANTAGES OF DSSC/SCA PROCESS:

ANLYSIS OF FINAL PRODUCTS

GAS ANALYSIS:

OIL ANALYSLS:

CARBON RESIDUE ANALYSLS:

PROCESS FLOW CHART

(CONVERSION OF WASTE PLASTIC INTO INDUSTRIAL FUEL)

PYROLYSIS REACTOR AND TECHNOLOGIS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF CATYLYST

COMPLETE PLANT SUPPLIERS

OTHER EQUIPMENT SUPPLIERS

SUPPLIERS OF ROTARY KILN

SUPPLIERS OF REACTOR

SUPPLIERS OF TRAY DRIER

SUPPLIERS OF HYDRAULIC LIFT

MANUFACTURER OF HEAVY MOBILE CRANES

SUPPLIERS OF TANKS

SUPPLIERS OF D.G. SET

SUPPLIERS OF BOILER

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)