Project Profile

For

Conversion of Waste Plastic

Into
Activated carbon & Industrial Fuel
(PROCESSING CAPACITY: 1 TPD)

Prepared By

Amol Kulkarni
Email: amolkul83@yahoo.com

Index
A)

Introduction

B)

Products to be manufactured

C)

Market potential

D)

Licenses for manufacture, storage and sale

E)

Production capacity

F)

Raw materials

G)

The fuel standards

H)

Applications of crude oil or industrial fuel

I)

Technology and manufacturing process

J)

Advantages of the manufacturing process

K)

Building

L)

Plant and machinery cost

M)

Quality control laboratory equipments

N)

Production cost for crude oil or industrial fuel

O)

Project cost

P)

Profitability analysis

10

Q)

Annexure I

11

R)

Annexure II

12

A) Introduction:
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.

1)
2)
3)
4)
5)
6)

The distillate fuel is an excellent fuel and can be used for

Diesel electrical generators
Diesel burners / stoves
Boilers
Hot air generators
Hot water generators
Diesel pumps

The distillate can be further fractionated into fuels as under and can be
used in automobiles.
1) Petrol
2) Kerosene
3) Diesel

B) Products to be manufactured:
Following products shall be manufactured from waste plastic
1) Crude oil
2) Petroleum Gases
3) Activated carbon
C) Market Potential:
There is great market potential for there fuels, as these can be sold at
about 25% less prices. The potential buyers shall be as under:
1) Industries having Boilers.
2) Industries having electric generators.
3) Hotels and Resorts having electric generators and diesel stoves.
4) Construction companies having heavy machinery.
5) Farmers using diesel pumps.
6) Indian Oil Corporation
7) Bharat Petroleum
8) Hindustan Petroleum
9) Indian Railways
10) Shops having electric generators
11) Domestic people having electric generators
12) Establishments having electric generators
13) State transport corporations
14) Local / City transports corporations
15) Logistics companies.
D) Licenses for manufacture, storage and sale:
No license is required for manufacture of crude oil.
For further refining of the petroleum products, application for mini refinery
should be submitted to Petroleum and Explosive Safety Organization
(PESO), Nagpur (Maharashtra). In addition license for storage should be
obtained from District Authority for storage above 25,000 liters.
E) Production Capacity:
Daily 1000 kg. waste plastic shall be processed per day in 3 shifts. On
and average, 700 liters of fuel is obtained from 1000 kg. municipal plastic
waste.

F) Raw Materials:
The raw materials include following:
1) Polyethylene: Buckets, drums, Chapels, sandal, bottles, plastic
parts, carry bags etc.
2) Polypropylene: Pipe fitting, filter cloths etc.
3) Polyamide: Nylon ropes
4) Polyvinyl Chloride (PVC): PVC pipes and fittings
5) Polystyrene: Cloths and fiber
6) Rubber: Tires, automobile parts
7) Electronic Goods: Telephone sets, computers, keyboards, monitors
laptops, electronic devices etc.
G) The Fuel Standards:
The fuels manufactured by processing of waste plastics will comply with
any statutory requirements or standards anywhere in the world. The key
indicators include flash point, viscosity, density etc. are within specified
standards for fuel.
The test report of the crude oil or industrial fuel obtained by plastic
processing is attached as annexure II.
H) Applications of the crude oil/industrial fuel:
Filtered crude oil can be used in:
a) boilers (replacement for LDO and furnace oil)
b) electric generators,
c) furnaces,
d) diesel stoves in hotels and food industries,
e) hot air generators,
f) hot water generators,
The purified fuels are suitable for all engines including road engines
such as trucks, buses, cars, motorcycle, as well as heavy machinery. The
diesel obtained by plastic process can replace virgin diesel fuel.

I) Technology and manufacturing process:

Research Centre for Fuel Generation (RCFG) has developed innovative
technology for cracking of plastics by inventing a new catalyst which cracks
the plastic more efficiently in short duration and the conversion of 1000 kg. of
mixed plastic gives about 700 liters crude oil or industrial fuel. In addition we
get about 15% hydrocarbon gas and about 80 kg. carbon black. 80 kg. carbon
black can be converted to 50 kg. activated carbon.
The technology developed is tested over the period of one year and is
economically viable.

J) Advantages of the manufacturing process:

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 fulfilled to some
extent at lower price.
5) No pollutants are created during cracking of plastics.
6) Any type of plastic or rubber can be proceed and converted into fuel.
7) The crude oil and the gas can be used for generation of electricity.

K) Building(Shed):
100 Sq.Mtrs.
Cost of shed = 100 X Rs. 6000 = Rs.6,00,000/L) Plant and Machinery Cost:
Qty
2
2
1

Description and Specifications

Conveyor for shredded plastic / rubber materials for feeding melting machine
Horizontal reactor screw type, processing capacity 110 kg. rubber or plastic
processing per hour with stirrer, condenser and receiver
Cooling tower: 100TR
6

Sparkler Filter: 8dia X 8 plates 1 HP

Gas collection tank with floating hood, M.S. 1,000 L

1 set

Machinery for manufacture of activated carbon from carbon black

1 set

Pipe fittings, process pumps and electrical fittings with control panel

Electricity generation set 40 KVA

1 set

Laboratory glassware and equipments

Cost of machinery = Rs. 28,00,000/+ Installation and commissioning Charges = Rs. 2,00,000/= Rs. 30,00,000/Note: Taxes as applicable extra
M) R. & D. AND Quality Control Laboratory Equipments:
1.
2.
3.
4.
5.
6.
7.

Specific gravity apparatus

Hot Air blower
Analytical balance
Hot plate
Glass distillation Unit
Water bath
Laboratory stirrer

N) Production cost for crude oil or industrial fuel:

Production cost per liter of crude oil:
Raw material: 1000 kg.
(mixed plastic waste) @ Rs. 5 per kg.
Chemicals /catalyst cost
Processing cost (electrical)
Fuel cost
Total Production cost for 700 liters crude
oil
Administrative cost + salaries

5,000
1,000
NIL
NIL
6,000
3,040

(Rs. 76000/25 days)

Total production cost for 700 liters
Production cost per liter of crude oil /
industrial fuel(Rs. 9040/700L)
Interest on capital investment / liter
(Rs. 493050/210000 liters)
Depreciation on fixed assets / liter
(Rs. 282500/210000 liters)
Production cost per liter of fuel

9,040
12.91
02.34
01.34
16.59

Production cost per kg. of activated carbon:

Raw material: 80 kg.
(carbon black as by-product)
Chemicals cost
Processing cost (electrical)
Fuel cost
Total Production cost for 50 kg. activated
carbon
Production cost per kg. of Activated
carbon

NIL
80
NIL
NIL
80
01.60

O) Project cost:
Basis:
Products to be manufactured
1) Crude oil 17,500 liters per month or 2,10,000 liters per year
2) Activated carbon 1,250 kg. per month or 15,000 kg. per year
Sr.
No.
PARTICULARS
A
FIXED ASSETS
Machinery + Pipe fittings +
Installation etc.
1
(As per list enclosed in K above)
2
Land (10000 sq.ft.)
3
Factory shed (100 sq. Meters
@ Rs. 3000/- per sq meter)
Lab. Equipments, Furniture &
4
Fixtures
Total Fixed assets:

Rs.

Rs.

Rs.

30,00,000
NIL
6,00,000
25,000
36,25,000 36,25,000

B.
1
A

One months production expenses

Raw Materials
Waste plastic 25,000 kg.

B
2
3
4
a)

Water and chemicals

Electrical expenses
Packing cost
Salaries
Manager 1x Rs.10,000 p.m.
Production Supervisor 3 x Rs. 5,000
b) pm
c) Helpers 9 x Rs.4,000/- p.m.
5
Administrative Cost: Office expenses,
transportation telephone etc.
Total one months recurring
expenses
Two months working capital
Fixed assets
Total Capital Investment
Total Project Cost
(In lacs) (round up)
6

Cost of production per annum

a) Fuel production cost
(Rs. 16.59 X 210000 Liters)
b) Activated carbon production cost
(Rs. 01.60 X 15000 kg.)
Total production cost
Yearly receipts:
a) Industrial fuel sale
(210000 liters X Rs. 30)
b) Activated carbon sale
(15000 kg. X Rs. 30)
Total receipts
Gross Profit per annum

1,55,000
1,25,000
30,000
NIL
NIL
61,000

NIL
NIL
61,000

10,000
15,000
36,000
15,000
2,31,000
4,62,000
36,25,000
40,87,000
33

34,83,900
24,000
35,07,900

63,00,000
4,50,000
67,50,000
32,42,100

P) Profitability analysis:
1) Rate of return =
=
=

(Profit per annum / Total capital investment) x 100

(3242100/4087000) X 100
79.33 %

2) Break Even Point

= [Fixed cost/(Fixed cost + Profit per annum)] x 100

= [2161550/ (2161550 + 3242100)] X 100
= [2161550/ 5403650] X 100
= 40.00 %

Fixed cost =
Depreciation on fixed assets
@ 10% pa

= Rs.

282500

+ Bank interest @ 15 % p.a.

= Rs.

493050

+ Recurring cost for 6 months

= Rs.

1386000

-----------------Rs.

2161550

10

Process FlowChart

Conversion of Waste Plastic into Industrial Fuel

Process

Machine

Material Balance
(5%Variable depending on

Collection of waste plastic

quality of Rawmaterial and catalyst)

Transportation of plastic
waste to factory

1000kg of plastic waste as

input

Cutting

Cutter

1000kg of cut plastic waste

Shredding of plastic

Plastic Shredder

1000kg of shredded plastic

Plastic melting

Plastic Melting machine

screwtype

1000L of molten Plastic

Plastic evaporation

Reactor

Plastic Vapours

Catalytic cracking of plastic

vapours

Catalyst chamber attached

to reactors

Fuel in Vapour form

Condensation

Condenser attached to
Catalyst chamber

Liquid Hydrocarbon Fuel

700L + Hydrocarbon gases

HDPE storage tank

Industrial Fuel 700 L

(Mixture of Petrol, Kerosene
and Diesel)

Sparkler Filter

Filtered Crude oil

Gas collection tank

Hydrocarbon Gases

In-line storage

Filtration

Storage

11

U) Annexure II:

Analysis report of crude oil / industrial fuel from waste plastic

SR.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

TEST
Density at @150 C
Acidity (mg KOH/gm)
API Gravity @ 600 F
Flash Point COC
Kinematic viscosity @ 400 C
Colour
Conradson Carbon residue
Asphaltine content
Ash Content
Calculated carbon aromatic
index
Pour Point
Sediment by extraction
Specific gravity @ 150 C
Sulphur content
Water by distillation
Colorific value
Distillation range
Initial boiling point
05% Recovery
10% Recovery
20% Recovery
30% Recovery
40% Recovery
50% Recovery
60% Recovery
70% Recovery
80% Recovery
85% Recovery
90% Recovery
Total Recovery

METHOD OF
TESTING
ASTM D 4052:2002
ASTM D 974:2002
ASTM D 1298:1999
ASTM D 92-05a
ASTM D 445:2005
ASTM D 1500:2004a
ASTM D 189:2005
ASTM D 3279:2001
ASTM D 482:2003
ISO 8217 :1996
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM
ASTM

D
D
D
D
D
D
D

97-05a
473:2002
4052:2002
4094:2003
95-05el
240 cal/g
86:04 b

RESULT
0.7930 gm/ml
0.76
46.67
<400 C
2.149 mm2/s
D8
0.010% (wt)
0.21% (wt)
< 0.01% (wt)
763.4
- 40 C
0.012 (wt)
0.7932
75 ppm
< 0.05% (vol)
10000
71.00 C
110.00 C
141.00 C
185.00 C
226.00 C
261.00 C
291.00 C
319.00 C
343.00 C
365.00 C
380.00 C
390.00 C
90% (vol)

13

Process Flow Chart: Conversion of Waste Tyre into Industrial Fuel

Process

Equipment Name

Material Balance per 24 hrs

(Variable depending on

Collection of waste Plastic.

quality of Raw material and catalyst)

Transportation of waste
Plastic to factory

1T of waste plastic

Shredding of Plastic

Agglomerator

1T of shredded plastic

Material Loading

Loading Conveyor

1T of shredded plastic loaded in

reactor

Plastic Melting

Reactor Number:1

1T of plastic in molten form

Reactor Number: 2 & 3

1T mixture of: Pyrolysis oil in

vapor form + Hydrocarbon
gases + Carbon Black

Saperation of
vapor phase

Vapor Column

0.85T mixture of: Pyrolysis oil in

vapor form + Hydrocarbon
gases

Condensation of
condensable fraction

Condensors

0.85T mixture of: Pyrolysis oil in

Liquid form + Hydrocarbon
gases

Liquid and gas saperation

Receivers

0.7MT of Pyrolysis oil Liquid at

bottom and 750kg of
hydrocarbon gas at top

Filtration and purification of

Pyrolysis oil

Filtration and purification

system

0.7T of Filtered and purified

Pyrolysis Oil

Storage of pyrolysis oil

outside building

Pyrolysis oil
undergroud storage

0.7T of Pyrolysis Oil (Industrial

Disel)

Storage Of gydrocarbon Gas

Hydrocarbon Gas Storage

Facility

150 KG of Hydrocarbon gas

Firing of hydrocarbon gas to

heat reactors, scrubbing of
flue gases and exhaust

Hot air generator, Suction

blowers, Scrubbing system,
Chimney

Plastic pyrolysis

150KG of Carbon Black that is

used as filler in plastic, rubber
and tyre recycling
Saperation of
solid phase

Carbon Black removal and

collection System