WASTE PLASTIC TO SYNTHETIC OIL

A
Project Report
Submitted in partial fulfillment of the requirements for the degree

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

by

1. Mane Sachin
2. Mohite Rushikesh
3. Patel Sahil Rafik
4. Urade Pranjali Deepak

Under the Guidance of

DHUMAL N. U.

Department of Mechanical Engineering

Karmaveer Bhaurao Patil College of Engineering,
Satara
SHIVAJI UNIVERSITY, KOLHAPUR
2019-2020
 Rayat Shikshan Sanstha's
Karmaveer Bhaurao Patil College of
Engineering, Satara

CERTIFICATE

This is to certify that, the work being presented in this project report
entitled “WASTE PLASTIC TO SYTHETIC OIL” In partial
fulfillment of the requirement for the award of the degree of Bachelor of
Engineering in Mechanical Engineering of Shivaji University, Kolhapur
Submitted bY Patel Sahil Rafik.
To the Department of Mechanical Engineering, KarmaveerBhaurao Patil
College of Engineering, Satara, is the record of the student’s own work that is
carried out under my supervision and guidance.

Date: / /20
Place: Satara

Guide Name & sign-

External sign-

Head,Mechanical Engg. Dept. Seal Principal

 DECLARATION

I hereby declare that the project entitled "WASTE PLASTIC TO

SYNTHETIC OIL" completed and written by me has not previously formed
the basis for award of any degree or diploma or other similar title of this or
any other university or examining body.

Date: / /20
Place: Satara Student
(PATEL SAHIL RAFIK)
 ABSTRACT

Waste plastic disposal and excessive use of fossil fuels have caused environment
concerns in the world. Both plastics and petroleum derived fuels are hydrocarbons
that
contain the elements of carbon and hydrogen. The difference between them is that
plastic molecules have longer carbon chains than those in LPG, petrol, and diesel
fuels.Therefore, it is possible to convert waste plastic into fuels.

All around the globe companies and individuals are starting to produce fuel from
waste plastic.
As only 8% of waste plastic is recycled in the U.S., 15% in Western Europe, and
much less in
developing countries, this reuse of plastic could potentially keep enormous
amounts of plastic
out of landfills and out of the oceans. Over 500 billion pounds of new plastic is
manufactured
each year and roughly 33% of that is single use and thrown away. As so little
plastic is recycled,
we need to reframe plastic waste as an underused resource vs. landfill destined. If
all plastic
waste made it into the landfill, it would surely be mined in the future, but
currently all plastic
waste does not make it into our landfills. The United Nations estimates plastic
accounts for four-
fifshs of the accumulated garbage in the world's oceans. We need to stop
polluting our oceans
with plastic before it is too late, and start collecting all plastics suitable for this
new fairly simple
technology, a technology that is available now.

The main objectives of this study were to understand and optimize the processes
of
plastic pyrolysis for maximizing the diesel range products.The technology is not
overly
complicated, plastics are shredded and then heated in an oxygen-free chamber
(known as
pyrolysis) to about 400 degrees celsius. As the plastics boil, gas is separated out
and ofsen reused
to fuel the machine itself. The fuel is then distilled and filtered. Because the entire
process takes
place inside a vacuum and the plastic is melted - not burned, minimal to no
resultant toxins are
released into the air, as all the gases and or sludge are reused to fuel the machine.
For this technology, the type of plastic you convert to fuel is important. If you
burn pure
 hydrocarbons, such as polyethylene (PE) and polypropylene (PP), you will
produce a fuel that
burns fairly clean. But burn PVC (Polyvinyl chloride), and large amounts of
chlorine will
corrode the reactor and pollute the environment.
 TABLE OF CONTENTS

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1
 LIST OF FIGURES

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2
 LIST OF TABLES

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3
 LIST OF ABBREVIATIONS

AACS Advanced Access Content System

ACI Adjacent Channel Interference
BER Bit Error Rate, Bit Error Ratio
CAMA Centralized Automatic Message Accounting

4
 ACKNOWLEDGEMENT

wish to express our profound gratitude and indebtedness to our

principal of K.B.P.COLLEGE OF ENGG, Mr.Sangale S.M.and Head of
Department of Mechanical engineering, Prof. Mrs. Shinde M.Y. for their
inspiring guidance, constructive criticism and valuable suggestions
throughout this project work. Our foremost courtesies go to our guide Prof.
Dhumal N.U. Without their contribution this seminar report would never
have been possible. Our deep gratitude is to our Professors and the entire
staff of the Mechanical Engineering Department and our friends, who
inspired us with their knowledge and understanding of subjects which
inspired us for doing this project.

5
 CHAPTER 1
INTRODUCTION
Plastics have become in indispensable part in today’s world. due to their light-
weight durability ,energy efficiency , coupled with a faster rate of production and design
flexibility ,these plastic are employed in entire gamut of industrial and domestic areas.

Plastic are non degradable polymers of mostly containing carbon, hydrogen and
few others elements such as chlorine, nitrogen etc…Due to its non-biodegradable nature.
The plastic waste contributes significantly to the problem of municipal waste
management.

 Plastic are natural / synthetic materials.

 They are produced by chemically modifying natural substances or are
synthesized from inorganic and organic raw material. on the basis of their
physical characteristics, plastics are usually divided into thermosets,
elastomers and thermoplastics .
 These groups differ primarily with regard to molecular structure, which is
what determines their differing thermal behavior .The following table lists
the characteristics of the various types of plastics.
So here we will convert waste plastic into diesel, plastics are shredded and then heated in
an oxygen-free chamber (known as pyrolysis) to about 400 degrees Celsius. As the
plastics boil, gas is separated out and often reused to fuel the machine itself. The fuel is
then distilled and filtered. Because the entire process takes place inside a vacuum and the
plastic is melted - not burned, minimal to no resultant toxins are released into the air, as
all the gases and or sludge are reused to fuel the machine.

6
 Fig-1.1 Diesel from waste plastic

Most of the big cities in country produces waste at a rate that outpaces its capacity
to collect and dispose it of in a safe and environmentally sound manner. Its current
approaches to waste management are neither effective nor sustainable. This necessitates a
paradigm shift in thinking. Traditional end-of-pipe solutions to waste management
problems only deal with symptoms of poor management and not the root causes.

However, Plastics have opened the way for new inventions and have replaced other
materials in existing products. They are light, durable and versatile, as well as resistant to
moisture, chemicals and decay. Yet these are the same properties that present
environmental challenges.

This strategy seeks to achieve sustainable plastic waste management practices that aim at:

 Methods of minimizing the production of plastic waste at source

 Initiating programs for stimulating a sound material cycle society that is based
on the 3R approach of reducing, reusing and recycling
 Developing an enabling policy framework for purposes of furthering the 3R
concept through economic and market based instruments
 Providing resources (technology, finance, and markets) for facilitating the
implementation of 3R policies
 Addressing appropriate technologies for increasing service coverage,
effectiveness, and environmentally sound modes of disposal
 Ensuring increased interaction and networking of all entities involved in 3R
activities, including end-users and consumers for purposes of creating new
business opportunities

7
  Building capacity and commitment through knowledge management and
transfer
 Facilitating and providing accurate and timely access to information by all
stakeholders through capacity building and institutional strengthening
 Creating a culture of green procurement
 To create an integrated approach to plastic waste management
The Government of India has taken initiative by starting movement of ‘Swachha Bharat’
to see a cleaner future of India. This program is really appreciable and giving hope to live
citizens in an enjoyable and safer environment.

CHAPTER 2

INTRODUCTION

Background

Plastic is a high molecular weight material that was invented by Alexander Parkes
in1862.Plastics are also called polymers. The term polymer means a molecule made up
by repetition of simple unit. For example, the structure of polystyrene can be written in a
form as shown in Figure 1-1 or in Figure 1-2.

8
The repeating unit of the polymer is in the brackets with a subscript, n, to
represent the number of the unit in this polymer molecule.
Plastic is one of the most commonly used materials in daily life which can be
classifiedin many ways such as based on its chemical structure, synthesis
process, density, andother properties. In order to assist recycling of the waste
plastic, Society of Plastic.

Industry (SPI) defined a resin identification code system that divides plastics into
the
following seven groups based on the chemical structure and applications :

• PET (Polyethylene Terephthalate)

• HDPE (High Density Polyethylene)

• PVC (Polyvinyl Chloride)

• LDPE (Low Density Polyethylene)

• PP (Polypropylene)

• PS (Polystyrene)

• Other

The above seven types of plastics are marked on various plastic products as
follows

9
Due to the convenience to manufacturing and use, the world plastic production has been
increasing since it was firstly commercially manufactured, from 1.5 million tons in1950
to 260 million tons in 2007 as shown in Figure 1-4. One of the major concerns for
extensive use of the plastics is the disposal of the waste plastic. In addition, the plastics
are produced from non-sustainable oil or coal, and thus it is a non-sustainable product.
There were 30.7 million tons of waste plastic generated in the U.S. in 2007, which
accounts for 12.1% of the total municipal solid wastes. In U.K., 4.9 million tons of
plastics were consumed in 2007. Europe consumes about 25% of the global plastic
production, which is equivalent to 60 million tons per year.

The process is really simple; it is similar to how alcohol is made. If you heat plastic waste
in non-oxygen environment, it will melt, but will not burn. Afser it has melted, it will
start to boil and evaporate, you just need to put those vapors through a cooling pipe and
when cooled the vapors will condense to a liquid and some of the vapors with shorter
hydrocarbon lengths will remain as a gas. The exit of the cooling pipe is then going
through a bubbler containing water to capture the last liquid forms of fuel and leave only
gas that is then burned. If the cooling of the cooling tube is sufficient, there will be no

10
fuel in the bubbler, but if not, the water will capture all the remaining fuel that will float
above the water and can be poured off the water. On the bottom of the cooling tube is a
steel reservoir that collects all the liquid and it has a release valve on the bottom so that
the liquid fuel can be poured out.

This device works on electricity (3 phase), it has six nichrome coils as heating elements
and consumes a total of 6kW (1kW each coil). The coils are turned on and off by three
solid state relays, one for each phase, the relays are controlled by a digital thermostat
with a temperature sensor just a bit below the lid, so that the vapor temperature can be
monitored. You need to heat the plastic slowly to about 350 degrees and just wait till it
does the magic. Our device has a capacity of 50 liters and can hold about 30 kg of
shredded plastic. The process takes about 4 hours, but it can be shortened considerably by
tweaking the design a bit.

As I said, this makes a liquid fuel that can be used as multifuel, that means it can be used
on diesel engines and also on gasoline engines, but we still need to test it will work on
gasoline. It works for diesel engines just fine, that has already been tested. There is a
difference in what plastic you use, if you use polyethylene (plastic cans, plastic foil, and
all kind of flexible non break plastics) you will get out liquid fuel that will solidify as it
cools into paraffin, it is still good for diesel engines as long as you use a heated fuel tank,
because it needs to be heated just about at 30 degrees celsius to be liquid and transparent.
If you don't want that, you can put the paraffin through the device for one more time and
you will chop those hydrocarbons even smaller and half of the paraffin will turn to liquid
fuel and other half will remain a paraffin, but much denser and will melt at higher
temperatures, this is the stuff you can make candles out of and it does not smell at all
when burned, maybe a bit like candles. But if you use polypropylene (computer monitor
cases, printer cases, other plastics that break easily), you get out only liquid fuel, no
paraffin at all. All you need is just filter the fuel out of solids and you good to go and put
it in your gas tank. We have made the analysis and it is almost the perfect diesel fraction.
It has no acids or alkalines in it, like fuel from tires does. The unit in the pictures can
convert about 60 kg of plastic into 60 liters of fuel in one day. Other methods of heating

11
the reactor can be employed, electricity is just easier to work with and control. Some
Japanese companies manufacture such devices, but their prices for this size unit is more
than 100 000$, our home made device cost us 900$ max. We use aluminum oxide bricks
to insulate the heat, they are light as foam and can be easily cut in any shape, but any
kind of insulator can be used. The bricks make the highest costs for this device. It can
also be made using liquid fuel burners to heat the reactor, this will enable to make the
device self-sustainable by using about 10-15% of the produced fuel along with the
produced gas.

A small farm can use a device this size and make fuel for itself by converting plastic
waste to fuel, farms have very much plastic waste and it is a big problem, at least in my
country. Our next goal is to make the same thing possible using biomass, every farm
could then use old leafs, wet grass, saw dust and all kind of biomass and gasify it into tar
like substance that can then be put through the pyrolysis device and turned into biodiesel.
But we will see about that.
With heavy consumption of fossil energy and fuels, the world will be faced with
shortage of energy and environmental concerns in the near future if no other solutions
are to be found. On the other hand, renewable energy sources and waste streams can
beprocessed for production of energy and fuels. Pyrolysis of waste plastic is an
economical method to solve waste plastic problem and to produce quality liquid fuel
which can have similar properties to the commonly used petroleum fuels.

Why plastic to oil

• It’s an alternative energy investment that makes sense

• It stimulates local economies and strengths communities.

• It creates partnership for sustainable energy production

• It’s an innovation that redefines recycling for a greener future

12
Factors affecting Plastic pyrolysis

The major factors influencing the plastic pyrolysis process and pyrolysis
productmolecular distribution include chemical composition of the feedstock,
crackingtemperature and heating rate, operation pressure, reactor type, residence time
andapplication of catalyst. These factors are summarized in this section as follows.

• Chemical composition of feedstock

The pyrolysis products are directly related to the chemical composition and chemical
structure of the plastics to be pyrolyzed. In addition, the chemical composition of the
feedstock also affects the pyrolysis processes. In reality, waste plastics are possibly
contaminated before recycling which could also have effects on the pyrolysis process and
products. As mentioned in Chapter 1, PE, PP and PS are most commonly used polymeric

13
hydrocarbons and were selected as the investigated materials in this study. Polyethylene
is formed from ethylene through chain polymerization which is shown in Formula 2-1.

• Cracking temperature and heating rate

Temperature is one of the most important operating variable, since the
temperaturedominates the cracking reaction of the polymer materials. Not all of the
polymermaterials can be cracked by increasing the temperature. Van der Waals force is
the forcebetween the molecules, which attracts molecules together and prevents the
collapse ofmolecules. When the vibration of molecules is great enough, the molecules
willevaporate from the surface of the object. However, the carbon chain will be brokenif
energy induced by van der Waals force along the polymer chains is greater than
theenthalpy of the C-C bond in the chain. This is the reason why high molecularweight
polymer is decomposed rather than is boiled when it is heated. In theory, thetemperature
of thermal breaking the C-C bonds should be constant for a given type ofplastic
(polymer). However, this temperature has been found to differ in differentstudies.

The other operating thermal dynamic parameter is heating rate. The term “heating rate”
in this field means the increase of temperature per unit time. The influence of theheating
rate on the plastic pyrolysis process and product distribution varies in differentstudies due
to the differences in the pyrolysis reactor, operation conditions (temperatureand
pressure), and temperature measurement location. Normally, in a fast or flashpyrolysis,
heating rate refers to the temperature change of the plastic from it dropped onthe hot
surface till decomposed and vaporized. The hot surface remains the temperaturewhile the
amount of plastic dropped on to it is relatively small. In this situation, theheating rate is
very high, up to 10,000 K/s. This is hard to be measuredprecisely. Therefore, the surface
temperature is normally applied as the reactiontemperature indicator rather than heating
rate in the flash and fast pyrolysis process. In abatch process, the plastic is normally

14
heated from room temperature to the crackingtemperature in several minutes. It is a slow
pyrolysis process. Once the plastic feedstockis heated to the cracking temperature, the
temperature remains relatively constant untilall feedstock has been pyrolyzed. Therefore,
heating rate is normally applied as thetemperature indicator instead of reaction
temperature in a slow pyrolysis process.

• Type of reactor
The reactor type for the plastic pyrolysis significantly influences on the heat transferrate,
mixing of plastics with pyrolysis products, residence time and the reflux level ofshe
primary products. Reactors can be classified into batch, semi-batch and continuousor
classified based on types of reactor bed.

• Residence time
The definition of residence time differs in various studies. In fast pyrolysis orcontinuous
pyrolysis process, it refers to the contact time of the plastic on the hotsurface throughout
the reactor. However in slow pyrolysis and batch process, the residence time means the
duration from the time when feedstock plastic start to beheated to the time when the
products are removed. Longer residence time favours afurther conversion of the primary
products thus yielding more thermal stable productssuch as light molecular weight
hydrocarbons, non-condensable petroleum gases. In a slow pyrolysis, long residence time
encourages the carbonizationprocess and produces more tar and char in the products. The
pyrolysis conditions,residence time and target products are given in Table 2-1.

15
• Use of catalyst
Advantages of using catalyst

In order to optimize plastic pyrolysis reactions and modify the distribution of

pyrolysisproducts, catalysts are widely used in research and industrial pyrolysis
processes.Petroleum fuels, such as LPG, petrol, kerosene, and diesel, are hydrocarbons
from C1 toC24. The PE pyrolysis products are mainly straight hydrocarbons from C1 up
to C80,which contain much more heaviermolecular weight components. One of the
mainpurposes of using catalysts is to shorten the carbon chain length of the
pyrolysisproducts and thus to decrease the boiling point of the products. Catalysts are
found to bemainly applied to PE pyrolysis because the primary product from other
plastics, such asPP and PS, are mainly light hydrocarbons, with similar carbon chain
length to the rangeof commercial fuels.

Catalyst classification
Homogeneous and heterogeneous catalysts have been studied for the catalytic
cracking of plastics. Homogeneous catalysts used for polyolefin pyrolysis have
mostly been classical Lewis acids such as AlCl3. Generally, heterogeneous
catalysts are preferred due to their easy separation and recovery from the
reacting medium. Heterogeneous catalysts can be summarized as
nanocrystalline zeolites, aluminiumpillared clays, conventional acid solids,

16
mesostructured catalysts, superacid solids, gallosilicates, metals supported on
carbon, and basic oxides.

• Pressure
Operating pressure has significantly effect on both the pyrolysis process and the
products. The boiling points of the pyrolysis products are increased under higher
pressure, therefore, under pressurized environment heavy hydrocarbons are
further
pyrolyzed instead of vaporized at given operation temperature.
Figure 2-10shows the effect of pressure on hydrocarbon number and their
fractions in the pyrolysisproducts of PE. In effect, under pressurized pyrolysis,
more energy is required forfurther hydrocarbon cracking. It was also found that
high pressure increases the yield ofnon-condensable gases and decreases the
yield of liquid products. (Figure 2-11) Theaverage molecular weight of gas
product also decreases with the increase of pressure.

17
• Other Influencing factors
There are a number of other factors which also affect pyrolysis process to a certainextent.
For example, reactive additives such as air, oxygen, or hydrogen are sometimes present in
the reaction for different purposes, which will interfere with the reactions andaffect the
quality of the products.

• Multi-factor effect on pyrolysis process

It is difficult to directly compare the product yields obtained for a specific plastic in
different researches as the operating conditions and reactors can be very different. In
general pyrolysis processes, thermal degradation occurs in the initial stages of the
pyrolysis with absence of oxygen. The pyrolytic products immediately afser the
pyrolysis consist of solid residue, oil vapour and non-condensable gases among which
the oil vapour will become liquid afser cooling down. According to the residence time
or the heating rate during the pyrolysis process, the pyrolysis can be classified into slow
carbonization, slow pyrolysis, fast pyrolysis, and flash pyrolysis.

18
LITERATURE SURVEY
2.1 LITERATURE REVIEW
All around the globe companies and individuals are starting to produce fuel
from waste plastic. As only 8% of waste plastic is recycled in the U.S., 15% in
Western Europe, and much less in developing countries, this reuse of plastic could
potentially keep enormous amounts of plastic out of landfills and out of the
oceans. Over 500 billion pounds of new plastic is manufactured each year and
roughly 33% of that is single use and thrown away. As so little plastic is recycled,
we need to reframe plastic waste as an underused resource vs landfill destined. If
all plastic waste made it into the landfill, it would surely be mined in the future,
but currently all plastic waste does not make it into our landfills. The United
Nations estimates plastic accounts for four-fifths of the accumulated garbage in
the world's oceans. We need to stop polluting our oceans with plastic before it is
too late, and start collecting all plastics suitable for this new fairly simple
technology, a technology that is available now.
The technology is not overly complicated, plastics are shredded and then
heated in an oxygen-free chamber (known as pyrolysis) to about 400 degrees
Celsius. As the plastics boil, gas is separated out and often reused to fuel the
machine itself. The fuel is then distilled and filtered. Because the entire process
takes place inside a vacuum and the plastic is melted - not burned, minimal to no
resultant toxins are released into the air, as all the gases and or sludge are reused
to fuel the machine.
For this technology, the type of plastic you convert to fuel is important. If you
burn pure hydrocarbons, such as polyethylene (PE) and polypropylene (PP), you
will produce a fuel that burns fairly clean. But burn PVC, and large amounts of
chlorine will corrode the reactor and pollute the environment. Burning PETE
releases oxygen into the oxygen deprived chamber thereby slowing the
processing, and PETE recycles efficiently at recycling centers, so it is best to
recycle PETE traditionally. HDPE (jugs) and LDPE (bags and films) are basically
polyethylene so usable as fuel as well, just slightly more polluting as a thicker

19
 heavier fuel is created. But additional processing can turn even HDPE into a clean
diesel.

Table 2.1 Summary of literature survey

Sr. Year of
Research
No Author Publica Topic Research
Methodology
. tion objective

S.L. Wong, N. Current state and future Pyrolysis

Ngadi, T.A.T. prospects of plastic waste
1 2015 Pyrolysis
Abdullah, I.M. as source of fuel: A review
Inuwa

Chika Catalytic pyrolysis of waste Idea of making

Muhammad, plastic from electrical and reactor
2 Jude A. 2015 electronic equipment Pyrolysis
Onwudili, Paul T.
Williams

WiwinSriningsih, Chemical analysis

Hydro-
Monica of fuel
Fuel Production from LDPE cracking of
GarbySaerodji,
Plastic Waste over Natural LDPE plastics
3 WegaTrisunarya 2014
Zeolite Supported Ni, Ni- into fuel over
nti, Triyono, Ria
Mo, Co and Co-Mo Metals bi functional
Armunanto,
catalysts
IipIzulFalah

20
 Pyrolysis technologies for Pyrolysis by 4 Collection of raw
municipal solid waste: A types of material for
Dezhen Chen, review reactors viz. process

4 Lijie Yin, Huan 2014 Fixed-bed,

Wang, Pinjing He Rotary
kiln,Fluidized-
bed, Tubular

Use of plastic waste as a Co pyrolysis Idea of using

M. Sajdak, R. fuel in the co-pyrolysis of of plastic plastic as a fuel
5 2014
Muzyka biomass. waste as fuel
with biomass

Hydrogen from waste Pyrolysis

Chunfei Wu and
6 2014 plastics by way of Pyrolysis
Paul T. Williams
pyrolysis-gasification

MochamadSyam Oil production

siroa, Fuel Oil Production from from waste
HarwinSaptoadi, Municipal Plastic Wastes in
Sequential
7 Tinton 2013 Sequential Pyrolysis and
pyrolysis
Norsujianto, Catalytic Reforming
PutriNoviasria, Reactors
Shuo Cheng

Development of process Conversion of Process learning

M. Punčochářa, for disposal of plastic High calorific

8 B. Rujb, P. K. 2012 waste using plasma value plastic

Chatterjeeb pyrolysis technology and into Synthesis
option for energy recovery gas (Syngas)

A. López , I. de Pyrolysis of municipal Plasma Various types of

9 2011
Marco, B.M. plastic wastes II: Influence pyrolysis pyrolysis

21
 Caballero, M.F. of raw material under N2
Laresgoiti, A. composition under atmosphere
Adrados, A. catalytic conditions
Torres

S.V.S. Rao, Treatment of Plastic Waste Various types of

Treatment by
Biplob Paul, A. G. by Melt Densification pyrolysis
Melt
10 Shanmugamani, 2011 Operational Experience at
densification
K. Paramasivan CWMF
at CWMF
and P. K. Sinha

Thermolysis of waste Various types of

plastics to liquid fuel A pyrolysis
Thermolysis
Achyut K. Panda, suitable method for plastic
of waste
11 R.K. Singh, D.K. 2010 waste management and
plastics to
Mishra manufacture of value
liquid fuel
added products—A world
prospective

D.S. Achilias, C. Chemical recycling of Various types of

Roupakias, P. plastic wastes made from pyrolysis
Chemical
12 Megalokonomos, 2007 polyethylene(LDPE and
recycling
A.A. Lappas, E.V. HDPE) and Polypropylene
Antonakou (PP)

Rafat Siddique, Recycled Use of waste

Use of recycled plastic in
13 Jamal Khatib, 2007 plastic in plastic
concrete: A review
Inderpreet Kaur concrete

Mechanical Recycling of
Recycling technologies for recycling, plastics
14 S.J. Pickering 2005 thermoset composite Thermal
materials—current status processing
and Pyrolysis

22
 processing

Catalytic cracking of Thermal Use of catalyst in

A.G. Buekens, H. plastics for recovery of Cracking by reaction of
15 1998
Huang gasoline-range using pyrolysis
hydrocarbons wastes catalysts

2.3 INTERPRETATION

Summary of collective outcome of research papers

Inference on plastic waste management from researchers work as below:

1. Recycling is best method than reuse and reduce; because plastic had become integral
part of life and cannot be avoided.
2. Plastic waste segregation from mixed municipal and industrial waste is the key issue
for research.
3. Incineration is fast and fetch ample amount of energy, but very harmful
environmental impact causing serious problems.
4. Pyrolysis is best and promising method in deep research for better results.
5. Pyrolysis will be a necessary need of tomorrow as a alternative source of fuel.
6. This project will help to decrease the pollution caused due to waste plastic.
7. It will be a initiative & a step towards Clean India.
8. It is a alternative source of fuel.
9. By using waste plastic as a raw material itself disposal of waste plastic.
10. Very less amount of process loss.
11. No need of engine modification.
12. Less amount of residue and large amount of product.
13. By segregating plastic from waste, we can use remaining waste for make of compost
fertilizers.
14. This is like cashing on the pollution itself because if this project is implement can
turn the tides globally by providing a long term solution for increasing waste of
plastic

23
 CHAPTER 3
PROBLEM DEFINATION
In Maharashtra from all 26 municipal corporations about 15000 to 18000 MT
Municipal Solid Waste is generated per day. Out of which on an average 7-8%
contribution is of plastic. Mumbai, Pune and Thane contribute more than 50% to total
MSW. Though the percentage of Plastic MSW is less, it is so harmful due to its
decomposition period of several million years. Indiscriminate littering of unskilled
recycling/reprocessing and non-biodegradability of Plastic waste raises the following
environmental issues:

 Indiscriminate dumping of plastic waste on land makes the land infertile due to its
barrier properties.
 Lead and Cadmium pigments, commonly used in LDPE, HDPE and PP as additives
are toxic and are known to leach out.
 During polymerization process fugitive emissions are released.
 During product manufacturing various types of gases are released.
 Non-recyclable plastic wastes such as multilayer, metalized pouches and other
thermoset plastic poses disposal problems.
 Sub-standard plastic carry bags, packaging films (<40µ) etc. pose problem in
collection and recycling.
 Burning of plastics generates toxic emissions such as Carbon Monoxide, Chlorine,
Hydrochloric Acid, Dioxin, Furans, Amines, Nitrides, Styrene, Benzene, 1, 3-
butadiene, CCl4, and Acetaldehyde.
 Littered plastics give unaesthetic look in the city, choke the drain and may cause
flood during monsoon.
 Recycling industries operating in non-conforming areas are posing threat to
environment to unsound recycling practices.

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3.1 AIM OF STUDY

In this scenario our project aims to solve the twin problem of

environment pollution due to plastic and the need for an alternative fuel
source.

The main aim of our project is to find a solution to the mountings

problem of plastic disposal, for which the plastic are converted into
useable fuel.

This Is Like Cashing on The Pollution Itself .This Project If Implement Can
Turn the Tides Globally by Providing a Long Term Solution for these
Problems.

Why plastic to oil

1. It’s an alternative energy investment that makes sense

2. It stimulates local economies and strengths communities.
3. It creates partnership for sustainable energy production
4. It’s an innovation that redefines recycling for a greener future

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 CHAPTER-4

OBJECTIVE

PRIMARY OBJECTIVE

The primary objective in our project is to convert waste plastic into oil.
Plastics from used bottles, milk bags etc. are made up of virgin plastics
that means we can recycle it again to make plastics, so from that we will
not going to make oil, recycled plastics will be more worthier than
making oil. But after recycling number of times the time comes when
plastic cannot be further recycled. This plastic has no option except to
dispose off or we can say throw away which will be like throwing money
and it will create environmental issues. So from this type of plastics we
will make oil. For example the waste and number of time reused plastics
from injection molding company. This oil will be the mixture of various
hydrocarbons like naphtha, petrol, diesel, kerosene etc.

 SECONDARY OBJECTIVE
The oil collected from waste plastic is mixture of number of fuels
which can be used for burning, it can replace furnace oil. Furnace oil
is dark viscous residual fuel obtained by blending mainly heavier
components from crude distillation unit, short residue and clarified oil
from fluidized catalytic cracker unit

26
WORKING METHODOLOGY
How to turn plastic waste into diesel fuel cheaply

The process is really simple; it is similar to how alcohol is made. If you heat
plastic waste in non-oxygen environment, it will melt, but will not burn. After it has
melted, it will start to boil and evaporate, you just need to put those vapors through a
cooling pipe and when cooled the vapors will condense to a liquid and some of the vapors
with shorter hydrocarbon lengths will remain as a gas. The exit of the cooling pipe is then
going through a bubbler containing water to capture the last liquid forms of fuel and
leave only gas that is then burned. If the cooling of the cooling tube is sufficient, there
will be no fuel in the bubbler, but if not, the water will capture all the remaining fuel that
will float above the water and can be poured off the water. On the bottom of the cooling
tube is a steel reservoir that collects all the liquid and it has a release valve on the bottom
so that the liquid fuel can be poured out. Here are some pictures to better understand the
design as shown in fig.5.1.
This device works on electricity (3 phase), it has nichrome coils as heating
elements and consumes a total of 1 kW. The coils are turned on and off by three solid
state relays, one for each phase, the relays are controlled by a digital thermostat with a
temperature sensor just a bit below the lid, so that the vapor temperature can be
monitored. You need to heat the plastic slowly to about 350 degrees and just wait till it
does the magic

27
The device has a capacity of 50 liters and can hold about 30 kg of shredded plastic. The
process takes about 4 hours, but it can be shortened considerably by tweaking the design
a bit. As I said, this makes a liquid fuel that can be used as multi fuel, that means it can be
used on diesel engines and also on gasoline engines, but we still need to test it will work
on gasoline. It works for diesel engines just fine, that has already been tested. There is a
difference in what plastic you use, if you use polyethylene (plastic cans, plastic foil, and
all kind of flexible non break plastics) you will get out liquid fuel that will solidify as it
cools into paraffin, it is still good for diesel engines as long as you use a heated fuel tank,
because it needs to be heated just about at 30 degrees Celsius to be liquid and transparent.
If you don't want that, you can put the paraffin through the device for one more time and
you will chop those hydrocarbons even smaller and half of the paraffin will turn to liquid
fuel and other half will remain a paraffin, but much denser and will melt at higher
temperatures, this is the stuff you can make candles out of and it does not smell at all
when burned, maybe a bit like candles. But if you use polypropylene (computer monitor
cases, printer cases, other plastics that break easily), you get out only liquid fuel, no
paraffin at all. All you need is just filter the fuel out of solids and you good to go and put
it in your gas tank. We have made the analysis and it is almost the perfect diesel fraction.
It has no acids or alkalines in it, like fuel from tires does. The unit in the pictures can
convert about 60 kg of plastic into 60 liters of fuel in one day. Other methods of heating
the reactor can be employed, electricity is just easier to work with and control. Some
Japanese companies manufacture such devices, but their prices for this size unit is more
than 100 000$, our home made device cost us 900$ max. We use aluminum oxide bricks
to insulate the heat, they are light as foam and can be easily cut in any shape, but any
kind of insulator can be used. The bricks make the highest costs for this device. It can
also be made using liquid fuel burners to heat the reactor, this will enable to make the
device self sustainable by using about 10-15% of the produced fuel along with the
produced gas. A small farm can use a device this size and make fuel for itself by
converting plastic waste to fuel, farms have very much plastic waste and it is a big

28
 problem, at least in my country. Our next goal is to make the same thing possible using
biomass, every farm could then use old leafs, wet grass, saw dust and all kind of biomass
and gasify it into tar like substance that can then be put through the pyrolysis device and
turned into biodiesel. The following figure shows actual model of converting fuel from
waste plastic.

COPPER JOINT
PIPE

GASKET
CONDENSER
COPPER COIL
HEATING
CHAMBER

T=4100
COLD WATER C

29
WASTE PLASTIC
DIESEL OIL
CHAPTER 3-DESIGN PRODUCERE

Theory of Shell of the pressure vessel

Types of shell- The main categories on large, in which the shells are classified, are

 Thin shells.
 Thick shells.
A cylinder is considered thin when the ratio of its inner diameter (d) to the wall thickness
(t) is more than 15 or equal.

When the ratio of inner diameter (d) to the wall thickness (t) is less than 15 it is considered as
a thick cylinder. Boiler shells, pipe tubes, storage tanks are the examples of thin walled cylinders
while hydraulic cylinders, high pressure pipes, gun barrels, submarines are thick walled
cylinders.

In this design, the shell used is a thin cylinder type as the shell thickness required is less as
compared to the storage capacity or the inner diameter of the vessel. In thin shells the stresses
are assumed to be uniformly distributed over the wall thickness and hence even the analysis
becomes simple and convenient.

Design failure of shell-

Stresses acting on the shell-

 Tangential or circumferential stress σt

One such type of stress is the hoop stress, which is defined for rotationally-symmetric
objects as the average force exerted circumferentially (perpendicular both to the axis
and to the radius of the object) in both directions on every particle in the cylinder wall.
𝑃𝑖 × 𝐷𝑖
𝜎𝑡 =
2×𝑡

30
1-Equation of tangential or circumferential stress

 Longitudinal Stresses σ1
It is defined for rotationally-symmetric objects as the average force exerted
lengthwise (parallel to the axis of the object) in both directions on every particle in the
cylinder ends.As the formulas for both the stresses suggest that circumferential stress is
twice more than longitudinal and hence, failure of the shell occurs because of this, and the
shell is cut lengthwise as shown in fig above. Hence this is taken as the design constraint for
the shell.

Thickness obtained above is added with a corrosion allowance of 1.5 to 4 mm.

Pi × Di
σt =
4t

2-Equation of longitudinal stresses

Compound cylinder:

Compound cylinders are used in high pressure applications, as it helps the structure straight
down in 2 ways-

31
  Provides external pressure fitting.
 Acts as insulation when high or low temperature fluid is stored in vessel.
Compound cylinders are advantageous as against simple single layered thickness shell.
Such shells are made by a process called Auto frottage wherein two concentric cylinders
with outer cylinder is shrunk in the inner one. This induces compressive stresses in the inner
one and reduces the net pressure acting on the cylinder. This is carried out by heating the
outer cylinder and expanding its diameter and then put on the inner one under gradual
cooling which makes it press fitted.Hence this is used in the design.

Supports for vessel:

Cylindrical and other types of vessels have to be supported by different methods. Vertical
vessels are supported by brackets, column, skirt, or stool supports, while saddles support
horizontal vessels. The choice of type of support depends on the height and diameter of the
vessel, available floor space, convenience of location, operating variables, the size of these
vessel, the operating temperature and pressure and the materials of construction. Brackets of
lugs offer many advantages over other types of supports. They are inexpensive, can absorb
diametrical expansions by sliding over greased or bronze plates, are easily attached to the vessel
by minimum amounts of welding, and easily leveled or shimmed in the field. Lug supports are
ideal for thick-walled vessels, but in thin-walled vessels, this type of support is not convenient
unless the proper reinforcements are used or many lugs are welded to the vessel.

It is also necessary to ensure that, the attachment of the support to the vessel, which is usually
by fillet welds should be able to transfer the load safely from vessel to support and that, the
support should be strong enough to withstand the load of the vessel.

SKIRT:

Vertical vessels are normally supported by means of suitable structure resting on a reinforced
concrete foundation. This support structure between the vessel and the foundation may consist
of a cylindrical shell termed as skirt. The skirt is usually welded to the vessel because the skirts
are not required to withstand the pressure in the vessel; the selection ofmaterial is not limited
to codes. The skirt may be welded directly to the bottom dished head, flush with the shell or to
the outside of shell. There will be no stress from internal and external pressure for the skirt,
unlike for the shell, but the stresses from dead weight and from wind or seismic bending
moments will be maximum.

32
ANCHOR BOLT:

The bottom of skirt of vessel must be securely anchored to the concrete foundations by means
of anchor bolts embedded in the concrete to prevent over turning from bending moments
induced by seismic and wind loads. The concrete foundation is poured with adequate
reinforcing steel to carry tensile loads. The anchor bolts may be formed from steel rounds
threaded at one end and usually with a curved or hooked end embedded in the concrete will
bond to the embedded surface of the steel.

Design of vessel

EN 10083 C45 steel plate high carbon steel

C45 steel sheet Physico-chemical testing items for products of the plant include tensile test

,hardness test ,impact test ,flattening test ,and chemical composition analysis ,etc .C20,C45 steel

pipes are manufactured by cold drawn process.

C45 is a medium carbon steel is used when greater strength and hardness is desired than in the

"as rolled" condition. Extreme size accuracy, straightness and concentricity combine to minimize

wear in high speed applications. Turned, ground and polished.

Soft Annealing

Heat to 680-710oC, cool slowly in furnace. This will produce a maximum Brinell hardness of 207.

33
Normalizing

Normalizing temperature: 840-880oC/air.

Hardening

Harden from a temperature of 820-860oC followed by water or oil quenching.

Tempering

Tempering temperature: 550-660oC/air.

C45 steel plate, EN 10083 C45 steel plate, under EN 10083 standard, we can regard C45 steel
plate as high carbon steel.

C45 steel plate is one mainly of high carbon steel,EN 10083 C45 steel plate is for quenching and
tempering. Technical delivery conditions for non alloy steels,these steels are for general
engineering purposes

Comparision of steel grades

JIS G 4051 S 45 C

C45 DIN 17200 C 45

EN 10083-2 NFA 33-101 AF65-C 45

Number:1.0503 UNI 7846 C 45

BS 970 070 M 46

UNE 36011 C 45 k

SAE J 403-AISI 1042/1045

Chemical Composition of EN C45 steel

34
 Grade C(%)min- Si(%)min- Mn(%)min- P(%)max S(%)max Cr(%)min-
max max max max

C45 0.42-0.50 0.15-0.35 0.50-0.80 0.025 0.025 0.20-0.40

Mechanical Properties of EN C45 steel

Grade Condition Yield Tensile Elon- Hardness Quenchi Benda- Nominal

Strength Strength ng Thickness,t
gation HRC bility
R°(Mpa) Rm Tempera 1.95mm≤t≤10.0
A5(%) ture mm
(Mpa)
(℃) Rolled Annea
led

Rolled 460 750 18 58 820 Min.reco- 2.0 1.0×t

mmended
Annealed 330 540 30 55 860 ×t
Bending
C45 Water- 2270 radius
quenched
1980 (≤90°)
Oil
quenched

Properties of steel C45 (1.0503) Properties of steel C45 (1.0503)

Weldability: Due to the medium-high carbon content it can be welded with

some precautions.
Hardenability: It has a low hardenability in water or oil; fit for surface
hardening that gives this steel grade a high hardness of the hardened
shell.

RAW MATERIAL & STANDARD MATERIAL

SR NO PART NAME MAT QTY COST

35
1 FRAME MS 20 kg 1000

450
2 CONDENSER TANK MS 1

HEATING COILHEATING 500

3 STD 1
COIL 2 KW

4 TOP CONE MS 1 400

800
5 HEATING CHAMBER MS 1

1200
6 CONDENSER MS 1

GLASS 1000
7 INSULATION 1
WOOL

1500
8 FLANGE MS 2

1400
9 GASKIT ASBESTOS 3

850
10 WIREING STD 1

100
11 NUT BOLT WASHER STD 12

150
12 RED OXIDE STD 1

2500
13 MISS -- ---

TOTAL

36
 FLOW DIAGRAM

WASTE PLASTIC GRINDING ADDING CATALYST

PYROLYSIS MELTING AND HEATING

BOILING

VAPOURISATION CONDENSATION OIL (MIXTURE OF

VARIOUS FUELS)

PARTIAL BOILING HEATING LOW TO

DISTILLATION HIGH TEMP

COLLECTION OF PETROL, DIESEL,

DIFFERENT OIL AT NAPTHA, KEROSENE,
DIFFERENT ETC
TEMPERATURE

Fig 5.3 Flow Chart : Operations to be performed during Pyrolysis

37
 RAW MATERIAL & STANDARD MATERIAL
SR COST
PART NAME MAT QTY
NO

1 FRAME MS 1 2800

450
2 TANK MS 1

HEATING COILHEATING 12000

3 STD 1
COIL 3 KW

4 TOP CIRCLE MS 1 700

1800
5 HEATING CHAMBER MS 1

1200
6 CONDENSER MS 1

GLASS 1000
7 INSULATION 1
WOOL

850
8 WIREING STD 1

100
9 NUT BOLT WASHER STD 12

150
10 RED OXIDE STD 1

2500
11 MISS -- ---

27600
TOTAL

38
 1) EXPECTED OUTCOME
The production of thermo fuel from waste plastics is one of the better methods to save
the environment profitably. From 1kg of raw plastic material we can get up to 700gm of
fuel & after distillation we will produce petrol, diesel, kerosene ,neptha, carbon & other
contents separately. One of the most beneficial part of this project is that “it provides
alternative to existing sources of fuels.” We here by conclude that our project will be a
pillar to save the environment and source for fuel. Here are some advantages of our
project:

 It is an alternative source of fuel.

 By using waste plastic as a raw material itself disposal of waste plastic.
 The carbon can be used in cartage refilling.
 Very less amount of process loss.
 No need of engine modification.
 Less amount of residue and large amount of product.
 By segregating plastic from waste, we can use remaining waste for make of
compost fertilizers.
 It is a huge contribution in mission “ Swachha Bharat” started by our PM

The contributors also focus on the effectiveness of recent technologies in mitigating

environmental impacts, particularly those for managing plastics in the solid waste stream.

Plastic and design engineers, polymers chemists, material scientists, and ecologists will
find plastics and the environment to be a vital resource to this critical industry.

39
 2) REFERENCES
3) A. López, I. de Marco, B.M. Caballero, M.F. Laresgoiti, and A. Adrados, A.
Torres, 2014, “Pyrolysis of municipal plastic wastes II: Influence of raw material
composition under catalytic conditions”, Waste Management, Volume 31, Issues
9–10, September–October 2011, Pages 1973–1983

4) A.G. Buekens, H. Huang, 1998, “Catalytic plastics cracking for recovery of

gasoline-range hydrocarbons from municipal plastic wastes”, Resources,
Conservation and Recycling 23 (1998) 163–181

5) Achyut K. Panda, R.K. Singh, D.K. Mishra, 2010, “Thermolysis of waste plastics
to liquid fuel A suitable method for plastic waste management and manufacture of
value added products—A world prospective”, Renewable and Sustainable Energy
Reviews, Volume 14, Issue 1, January 2010, Pages 233–248

6) Chika Muhammad, Jude A. Onwudili, Paul T. Williams, 2015, “Catalytic

pyrolysis of waste plastic from electrical and electronic equipment”, Volume 113,
Pages 332–339

7) Dezhen Chen, Lijie Yin, Huan Wang and Pinjing He, 2015, “Pyrolysis
technologies for municipal solid waste: A review”, Waste Management, Volume
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8) D.S. Achilias, C. Roupakias, P. Megalokonomos, A.A. Lappas, E.V. Antonakou,

2007, “Chemical recycling of plastic wastes made from polyethylene (LDPE and
HDPE) and polypropylene (PP)”, Volume 149, Issue 3, pages 536-542

9) Elena Friedrich and Cristina Trois, 2011, “Quantification of greenhouse gas

emissions from waste management processes for municipalities – A comparative
review focusing on Africa”, Volume 31, Issue 7, July 2011, Pages 1585–1596

10) Jefferson Hopewell, Robert Dvorak and Edward Kosiors, 2009, “Plastics
recycling: challenges and opportunities”, Phil. Trans. R. Soc. B (2009) 364,
2115–2126

11) Kemal Ozkan, Semih Ergin, Sahin Isık and Idil Isıklı, 2015, “ A new
classification scheme of plastic wastes based upon recycling labels”, Waste
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