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)
