VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana sangama, Belagavi, Karnataka – 590 018

Project Report
On
“DESIGN AND FABRICATION OF MACHINE TO CONVERT PLASTIC
INTO OIL AND GASEOUS FUEL PRODUCTION”
(SPONSERED BY KSCST)

Submitted in partial fulfilment of the requirement for the award of degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
SUBMITTED BY
Sital Kumar Sah 1NH14ME161
Sandeep Chaudhary 1NH14ME157
Suraj Timilsina 1NH14ME164
Nischal Bhattarai 1NH14ME154

Under the guidance of

Mr. Lakshmana Naik
Asst. Professor,
Department of Mechanical Engineering,

DEPARTMENT OF MECHANICAL ENGINEERING

NEW HORIZON COLLEGE OF ENGINEERING
BANGALORE-560 103
2017-18
 DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
It is certified that the project entitled “Design and fabrication of machine to convert
plastic into oil and gaseous fuel production” is work carried out by Sital Kumar Sah,
Sandeep Chaudhary, Suraj Timilsina, Nischal Bhattarai a bonafide student of New
Horizon College of Engineering, Bangalore in partial fulfilment for the award of degree
of Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya
Technological University, Belgaum during the year 2017-18. It is further certified that
all corrections/suggestions indicated for internal assessment has been incorporated in the
report deposited in the departmental library.The Project Report has been approved as it
satisfies the academic requirements in respect of Project Work prescribed for the said
degree.

Signature of the guide Signature of the HOD Signature of the Principal

Mr. Lakshmana Naik Dr. M S GANESHA PRASAD Dr. Manjunatha
Asst. Professor Dean-Student Affairs & HOD-ME, Principal
Dept. of Mechanical Engineering. Dept. of Mechanical Engineering. NHCE

Name(s) of the student: University Seat Number(s):

1. Sital Kumar Sah 1NH14ME161

2. Sandeep Chaudhary 1NH14ME157

3. Suraj Timilsina 1NH14ME164

4. Nischal Bhattarai 1NH14ME154

External Examiner(s) Signature with Date

1.

2.
 ACKNOWLEDGEMENT
“The gratification and euphoria that accompany the successful completion would
be incomplete without the mention of the people who made it possible, whose constant
guidance and encouragement served as a beacon of light and crowned are efforts with
success.”

We are extremely thankful to our internal guide Mr. Lakshmana Naik, Assistant
professor, Mechanical Department, N.H.C.E, for his constant support, encouragement
and valuable guidance throughout the period of the project.

We wish to express our gratitude to Dr. M. S. Ganesha Prasad, H.O.D,

Department of Mechanical Engineering, N.H.C.E, for providing a good working
environment and for his constant support and encouragement.

We would like to express our sincere thanks to Dr. Manjunatha, Principal,

N.H.C.E, for his encouragement that motivated us for successful completion of project
work.

We express our heartfelt thanks to Dr. Mohan Manghnani, Chairman,

N.H.C.E, for providing all the facilities for carrying out the project.

We would like to profoundly thank our Management, New Horizon College of

Engineering for providing such a healthy environment for successful completion of
project work.

Finally, we thank all the staff of N.H.C.E Mechanical Department and those who
have helped us and contributed directly and indirectly towards the successful completion
of the project work and also our parents for providing unconditional support and
encouragement for caring out the project work.
 DECLARATION
We SITAL KUMAR SAH, SANDEEP CHAUDHARY, SURAJ TIMILSINA,
NISCHAL BHATTARAI, student of final semester B.E Mechanical Engineering. New
Horizon College of Engineering, Bengaluru, hereby declare that the dissertation
entitled “DESIGN AND FABRICATION OF MACHINE TO CONVERT PLASTIC
INTO OIL AND GASEOUS FUEL PRODUCTION” has been carried out by my
group and submitted in partial fulfillment of the requirement of the award of B.E in
Mechanical engineering by New Horizon College of Engineering, Bengaluru during
the academic year 2017-2018. Further the matter embodied in the dissertation has not
been submitted previously by anybody for the award of any Degree or Diploma to any
other University.

PLACE: BENGALURU SITAL KUMAR SAH (1NH14ME161)

SANDEEP CHAUDHARY (1NH14ME157)
DATE: SURAJ TIMILSINA (1NH14ME164)
NISCHAL BHATTARAI (1NH14ME154)

CERTIFICATE
This is to certify that the above declaration made by the candidates is correct to the best
of my knowledge and belief.

PLACE: BENGALURU Mr. Lakshmana Naik

DATE: Assistant professor,
Dept. of Mechanical Engineering
N.H.C.E, Bengaluru
 ABSTRACT
Plastic was invented by Alexander Parkes in 1860. Plastics have become a crucible
part in today’s world. Due to their light weight, durability, design flexibility, they are
excessively used in industry as well as household and other fields. The demand for plastic
is increasing day by day which now pose a tremendous threat to the environment. The
study focus on the design and fabrication of machine to convert plastic into oil as an
effort in finding environment-friendly means of waste recycling by means of pyrolysis. It
is an alternative solution to increasing problem of waste disposal. Pyrolysis keeps running
without oxygen and in high temperature of around 250°C for which reactor is
manufactured to give the expected temperature to the response.
The waste plastics are subjected to depolymerisation, pyrolysis, catalytic cracking
and fractional distillation to obtain different value added fuels such as petrol, kerosene,
and diesel. Our Project deals with the extraction of oil from the waste plastics termed as
plastic pyrolysed oil which can be marketed at much cheaper rates compared to that
present in the market. As we know that both Plastics and Petroleum derived fuels are
Hydrocarbons that contain the elements of Carbon & Hydrogen.
Pyrolysis process becomes an option of waste-to-energy technology to deliver
bio-fuel to replace fossil fuel. The advantage of the pyrolysis process is its ability to
handle unsort and dirty plastic. The pre-treatment of the material is easy. Plastic is needed
to be sorted and dried. Pyrolysis is also nontoxic or non-environmental harmful emission
unlike incineration. In this investigation, plastic waste (poly propylene) are utilized for
pyrolysis to get fuel oil that has comparable physical properties as the energizes like
petroleum, diesel and so on Converting waste plastics into fuel hold great promise for
both the environmental and economic scenarios.
 TABLE OF CONTENTS
Page NO.
1. Introduction 1-10
1.1. Different types of plastic 2-4
1.1.1. Polyethylene terephthalate 2
1.1.2. High-density polyethylene 2
1.1.3. Polyvinyl chloride 2-3
1.1.4. Low density polyethylene 3
1.1.5. Polypropylene 3
1.1.6. Polystyrene 3-4
1.1.7. Mixed plastic 4
1.2. Plastic in environment 5-7
1.2.1. Pyrolysis process 6
1.2.2. Environment hazards due to mismanagement of plastic waste 6-7
1.2.3. Side effect of plastic in nature 7
1.3. Wastes plastic 7-10
1.3.1. Municipal plastic wastes 8
1.3.2. Industrial plastic wastes 9
2. Problem statement 11
3. Literature review 12-16
3.1. Outcome of literature survey 16
4. Objectives 17
5. Methodology 18-23
5.1. Pyrolysis process 18
5.2. Pyrolysis of plastic 19
5.3. Step involves in process 19-23
5.3.1. Collection and segregation of plastic 20
5.3.2. Feeding into reactor 20-21
5.3.3. Heating 21
5.3.4. Condensing 22
5.3.5. Liquid collection 22
5.3.6. Distillation 23
5.3.7. Testing 23
6. Experimental setup 24-31
6.1. Introduction 24
6.2. Working of pyrolysis process 24-25
6.3. Design details 25-31
6.3.1. Reactor 25-26
 6.3.2. Condenser tank 27
6.3.3. CAD model of setup 28
6.3.4. Heater 28-29
6.3.5. Controller and indicator 29-30
6.3.6. Sensor 30
6.3.7. Distillation Setup 30-31
7. Properties of fuel 32
8. Result and discussion 33-35
9. Economy of the fuel product 36
10. Comparision of properties of plastic with diesel and petrol 37
11. Advantages and limitations 38
12. Application of project & future work 39
13. Conclusion 40
14. Bill of materials 41
15. References 42-43
 LIST OF FIGURE
Figure No. Figure Name Page No.
1.1 Different types of plastic 4
1.2 Plastic generation and the amount of plastic that is subjected to recycling 8
2.1(a) Gas heating process 11
2.1(b) Electric heater process 11
5.1 Breaking of hydrocarbon chain in pyrolysis process 18
5.2 Flow diagram of process 19
5.3 Collection of plastic 20
5.4 Plastic feeding into reactor 21
5.5 Heating element 21
5.6 Condensing process 22
5.7 Liquid collector 22
5.8 Distillation process 23
5.9 Oil sample 23
6.1 Block diagram of Pyrolysis process 24
6.2 Experimental setup 25
6.3 Reactor unit 26
6.4 Condenser tank 27
6.5 CAD assembled view of setup 28
6.6 Heater 29
6.7 Temperature controller and indicator 29
6.8 Sensor 30
6.9 Distillation process setup 31
8.1 Cleveland apparatus 33
8.2 Redwood viscometer 34
 LIST OF TABLE
Table No. Table name Page No.
1.1 Degradability of different waste materials 6

1.2 Disposal methods of waste plastics & their advantages and Disadvantages 9-10

8.1 Expected Outcome of pyrolysis plant 35

10.1 Comparision of properties of plastic with diesel and petrol 37

Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 1

INTRODUCTION
Plastics are one of the most commonly used materials in our daily life and offer
remarkable contribution to the society. They are widely used in packaging and
manufacture of products including electronic, automotive, etc. Plastics are light weight
and can be simply formed. They show non-corrosive behavior. They are reusable and
conserve natural resources. Resultantly, there has been a quick development in plastic
utilization and plastics have been utilized as substitution to wood and metals.

Plastic was invented by Alexander Parkes in 1860 and has high molecular mass.
They are synthetic organic materials produced by polymerization. They may contain other
substances besides polymers to reduce costs and to improve performance. Desired shape
can be given to these polymers by molding or by extrusion Pyrolysis involves the heating
and degradation of the polymeric materials at temperatures between 250°C and 350°C
without oxygen bringing about the arrangement of a carbonized singe (strong deposits)
and an unpredictable division which might be isolated into condensable hydrocarbon oil
and a non-condensable high caloric esteem gas. Scheirs expressed that gases framed amid
the pyrolysis of natural material incorporate carbon monoxide, hydrogen, methane,
carbon dioxide, water, and hydrocarbons, similar to ethane, ethane, propane, propane,
butane, and so forth. The temperature and heating rates can be controlled to produce
desired solid, gas and liquid products because they have considerable influence in the
pyrolysis process. Yin have considered pyrolysis of waste plastic as one of the most
feasible large-scale methods of energy regeneration. This is because waste plastic is a
valuable source of liquid and gas fuels as well as chemicals.

Mainly there are two types of plastics: thermoplastics and thermosetting plastic. If
enough heat is supplied, thermoplastics can be softened and melted repeatedly. On
cooling, they are hardened, so that they can be made into new plastics products. Examples
are polyethylene terephthalate, polystyrene,polyvinyl chloride, high-density polyethylene,
low-density polyethylene, poly propylene etc. They are recyclable. Thermosets or
thermosetting plastics can be melted and shaped only once. It is not good to repeatedly
heat treat such plastics; therefore they remain in solid state after they have been solidified.
Examples are epoxy resin, phenol formaldehyde and urea formaldehyde.

In India alone, the demand for the plastics is about 8 million tons per year. More than
10,000 metric tons per day plastics are produced in India and almost the same amount is

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

imported by India from other countries. The per capital consumption of plastics in India is
about 3kg when compared to 30kg to 40kg in the developed countries. Most of these
come from packaging and food industries. Most of the plastics are recycled and
sometimes they are not done so due to lack of sufficient market valve of the waste plastics
not recycled about 43% is polyethylene, with most of them in containers and packaging.

1.1. Different types of plastics

1.1.1. Polyethylene terephthalate (PET)

PET has become the great choice for plastic packaging for various food products,
mainly beverages such as mineral water, soft drink bottle and fruit juice containers. This
is due to its intrinsic properties that are very suitable for large-capacity, lightweight and
pressure-resistant containers. Different utilizations of PET incorporate electrical
protection, printing sheets, attractive tapes, X-ray and other photographic film [19]. The
extensive applications of PET would cause an accumulation of PET waste in the landfill.
Recycling PET waste was the current practice of handling accumulated plastic waste. In
any case, the massiveness of the holders causes high recurrence of accumulations and
along these lines, builds the vehicle costs. To ease the recycling process, the PET waste
needs to be sorted into different grades and colors that make its recovery inefficient and
uneconomical. Subsequently, other option for PET recuperation, for example, pyrolysis
process has been investigated and the item yield was broke down by a few specialists.

1.1.2. High-density polyethylene (HDPE)

HDPE is characterized as a long linear polymer chain with high degree of
crystallinity and low branching which leads to high strength properties. Because of its
high quality properties, HDPE is generally utilized as a part of assembling of drain
bottles, cleanser bottles, oil compartments, toys and the sky is the limit from there. The
various applications contribute about 17.6% in plastic waste category which is the third
largest plastic type found in municipal solid waste (MSW) [20]. HDPE waste have an
awesome potential to be utilized as a part of pyrolysis process since it can deliver high
fluid yield relies upon the set up parameters. Numerous examinations have been led on
HDPE pyrolysis at various working parameters to research the item yield acquired.
1.1.3. Polyvinyl chloride (PVC)
Unlike other thermoplastics such as polyethylene (PE), polystyrene (PS) and
polypropylene (PP) which can be softened by heating and solely derived from oil, PVC is
exceptional since it is manufactured from the mixture of 57% chlorine (derived from

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Industrial grade salt) and 43% carbon (derived from hydrocarbon feedstock such as
ethylene from oil or natural gas) [21]. The chlorine property makes PVC an excellent fire
resistance, thus very suitable for electrical insulation. The compatibility PVC to be mixed
With many additives makes it a versatile plastic. Regular applications of PVC include
wire and cable insulation, window frames, boots, food foil, medical devices, blood bags,
automotive interiors, packaging, credit cards, synthetic leather, etc. Even though it has
wide applications, the research done on the PVC pyrolysis found in the literature was
very less due to the dangerous substance that it tend to release when heated at high
temperature.
1.1.4. Low-density polyethylene (LDPE)
As opposed to HDPE, LDPE has all the more stretching that outcomes in weaker
intermolecular power, in this manner bring down elasticity and hardness. Be that as it
may, LDPE has preferable flexibility over HDPE since the side stretching makes the
structure be less crystalline and simple to be shaped. It has a superb protection from
water, along these lines generally connected as plastic sacks, wrapping foils for bundling,
waste packs and significantly more. All these items are commonly used in our daily lives
and therefore, LDPE waste has been accumulated day by day that it is known as the
second largest plastic waste in MSW after PP [20]. As one approach to recoup vitality and
lessen squander, pyrolysis of LDPE to oil item has gotten much consideration by
scientists these days.
1.1.5. Polypropylene (PP)
PP is a saturated polymer with linear hydrocarbon chain that has a good chemical
and heat resistance. Unlike HDPE, PP does not melt at temperature below than 160oC. It
has a lower thickness than HDPE yet has higher hardness and unbending nature that
makes it ideal in plastic industry. PP contributes around 24.3% in plastic squanders class
which are the biggest measure of plastics found in MSW [20]. The diverse applications
include flowerpot, office folders, car bumpers, pails, carpets, furniture, storage boxes and
more. The high demand of PP in daily life causes the amount of PP wastes to increase
each year and therefore, pyrolysis of PP is one of the methods that can be used for energy
recovery. A few analysts have researched the pyrolysis of PP at different parameters to
gauge the fluid oil yield and properties.
1.1.6. Polystyrene (PS)
PS is made of styrene monomers obtained from the liquid petrochemical. The
structure consists of a long hydrocarbon chain with phenyl group attached to every other
carbon atom. PS is naturally colorless but it can be colored by colorants. It is warm

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

flexibility and it offers sensible sturdiness, quality and delicacy that make this polymer
alluring to be utilized as a part of assortment of areas, for example, in nourishment
bundling, hardware, development, medicinal, apparatuses and toys. The wide range of
applications signifies the large waste amount of PS in MSW accumulated each year.
Unfortunately, PS is excluded in the roadside reusing program in which the reusing
canisters just included glasses, papers, jars, and certain plastics. Even though there is a
plastic category, normally people will not throw the foam food packaging into plastics
recycle bin and they often go to the general bin. In this way, PS is for the most part not
isolated and not financially to gather for reusing because of its low thickness polystyrene
froth. Henceforth, the main way the PS waste can be completely used is through pyrolysis
process in which it can be transformed into more profitable oil item instead of to wind up
in the landfills for eternity.
1.1.7. Mixed plastics
As already said, pyrolysis process has an additional favorable position over the
reusing procedure since it needn't bother with an extreme arranging process. In recycling
process, most plastics are not compatible with each other to be processed together during
recycling. For example, a slight measure of PVC contaminant introduce in PET reuse
stream will debase the entire PET gum by getting to be yellowish and weak that requires
reprocessing [22].This shows that recycling process is very sensitive to contaminants that
it requires all plastics to be sorted based on type of resins, colors and transparency.
However, pyrolysis process seems to be more sustainable since liquid oil still can be
produced from the mixed plastics in the feedstock. This has been encountered by several
researchers who conducted studies of mixed plastics pyrolysis.

Fig 1.1 Different types of plastic.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

1.2. Plastics in Environment

Economic growth and changing consumption and production patterns are resulting
into rapid increase in generation of waste plastics in the world. For more than 50 years the
global production of plastic has continued to rise. Some 299 million tons of plastics were
produced in 2013, representing a 4 percent increase over 2012. Recovery and recycling,
however, remain insufficient, and millions of tons of plastics end up in landfills and
oceans each year approximately 10–20 million tons of plastic end up in the oceans each
year. A recent study conservatively estimated that 5.25 trillion plastic particles weighing a
total of 268,940 tons are currently floating in the world’s oceans. And since plastic being
a non-biodegradable material it remains into the soil, thereby polluting the environment.

On the other hand, Plastics play an important role in day-today life, as in certain
application they have an edge over conventional materials. Indeed, their light weight,
durability, energy efficiency, coupled with a faster rate of production and more design
flexibility, have allowed breakthroughs in fields ranging from non-conventional energy,
to horticulture and irrigation, water-purification systems and even space flight. However
one has to accept that virtues and vices co-exist. Plastics are relatively cheaper and being
easily available has brought about use and throwaway culture. Plastics waste management
has become a problem world over because of their non-degradable property. A majority
of landfills, allotted for plastic waste disposal, are approaching their full capacity. Thus
recycling is becoming increasingly necessary.

In a short span of five years plastics have captured 40% of total 6.79 billion USD
packaging market in India. This situation may grow further in the coming years with
more and more US and European companies entering the market. It would be very
interesting to note the type of litter we generate and the approximate time it takes to
degenerate. Table 1.2 shows the time taken to degenerate for different waste materials.

India has been used as a dumping ground for plastic waste, mostly from
industrialized countries like Canada, Denmark, Germany, UK, Netherlands, Japan, France
and the United States.

Each year more than 100 million tons of plastic are produced worldwide. Though
plastics have opened the way for a plethora of new inventions and devices it has also
ended up clogging the drains and becoming a health hazard. The plastic waste accounts to
about 10 thousand tons per day in India. At these alarming levels of waste generation,
India needs to set up facilities for recycling and disposing the waste.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Degradability of different waste materials

Type of litter Time for degradation
Organic wastes, paper, etc 1-3 weeks
Cotton cloth 8-20 weeks
Wood 10-15 years
Tin, aluminium, etc 100-500 years
Plastics A million years
Table 1.1 Degradability of different waste materials
Plastics waste may grow in India in future because more and other countries like
as U.S, China and U.K will comes in Indian market. There is a much wider scope for
recycling in developing countries mainly in India due to low labour cost, plastics
consumption increase and therefore raw materials increase. As we know that both Plastics
and Petroleum derived fuels are Hydrocarbons that contain the elements of Carbon &
Hydrogen. Pyrolysis process becomes an option of waste-to-energy technology to deliver
bio-fuel to replace fossil fuel. The advantage of the pyrolysis process is its ability to
handle unsort and dirty plastic. The pre-treatment of the material is easy. Plastic is needed
to be sorted and dried. Pyrolysis is also no toxic or non-environmental harmful emission
unlike incineration.

1.2.1. Pyrolysis Process

Pyrolysis is the chemical decomposition of organic substances by heating the
word is originally coined from the Greek-derived elements pyro "fire" and pyrolysis
"decomposition". Pyrolysis is usually the first chemical reaction that occurs in the
burning of many solid organic fuels, cloth, like wood, and paper, and also of some kinds
of plastic. Anhydrous Pyrolysis process can also be used to produce liquid fuel similar to
diesel from plastic waste. Pyrolysis technology is thermal degradation process in the
absence of oxygen. Plastic waste is treated in a cylindrical reactor at temperature of 300ºC
– 350ºC. Now a days plastics waste is very harmful to our nature also for human beings
.plastic is not easily decomposable its affect in fertilization ,atmosphere ,mainly effect on
ozone layer so it is necessary to recycle these waste plastic into useful things .so we
recycle this waste plastic into a useful fuel.

1.2.2. Environmental hazards due to mismanagement of plastics waste

Plastics are no biodegradable material. It takes time to biodegrade is 300-500 years
and therefore environmental hazards due to improper manage include following aspect:

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

1. Littered plastics spoils beauty of the city and choke drains and make important
public places dirty.
2. Garbage containing plastics, when burnt may cause air pollution by emitting
polluting gases.
3. Garbage mix with plastics gives problem in landfill operation.
4. Lack of recycling plant to posing unhygienic problem to environment
1.2.3. Side Effect of plastics in nature
1. Durability and chemical structure greatly influences the biodegradability of some
organic compounds therefore an increased number of functional groups (groups of
atoms) attached to the benzene ring in an organic molecule usually hinders microbial
attack.
2. Instead of biodegradation, plastics waste goes through photo-degradation and turns
into plastic dusts which can enter in the food chain and can cause complex health
issues to earth habitants.
3. Plastics are produced from petroleum derivatives and are composed primarily of
hydrocarbons but also contain additives such as antioxidants, colorants, and other
stabilizers.
4. However, when plastic products are used and discarded, these additives are
undesirable from an environmental point of view.
5. Burning of plastics give NOX, COX, SOX, particulate, dioxins, furans and fumes to
increase air pollution with result acid rain and increase global warming.
6. Plastics in land fill area leaching of toxins into ground water.

1.3. Wastes Plastic

Waste plastics are one of the most promising resources for fuel production
because of its high heat of combustion and due to the increasing availability in local
communities. Unlike paper and wood, plastics do not absorb much moisture and the water
content of plastics is far lower than the water content of biomass such as crops and
kitchen wastes. The conversion methods of waste plastics into fuel depend on the types of
plastics to be targeted and the properties of other wastes that might be used in the process.
Additionally the effective conversion requires appropriate technologies to be selected
according to local economic environmental, social and technical characteristics. In
general, the conversion of waste plastic into fuel requires feedstock which are non-
hazardous and combustible. In particular each type of waste plastic conversion method
has its own suitable feedstock. The composition of the plastics used as feedstock may be

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

very different and some plastic articles might contain undesirable substances (e.g.
additives such as flame retardants containing bromine and antimony compounds or
plastics containing nitrogen, halogens, Sulphur or any other hazardous substances) which
pose potential risks to humans and to the environment. The types of plastics and their
composition will condition the conversion process and will determine the pre-treatment
requirements, the combustion temperature for the conversion and therefore the energy
consumption required, the fuel quality output, the flue gas composition (e.g. formation of
hazardous flue gases such as NOx and HCl), the fly ash and bottom ash composition, and
the potential of chemical corrosion of the equipment.

Fig 1.2
The plastic generation and the amount of plastic that
Is subjected to recycling

1.3.1. Municipal Plastic wastes

Municipal plastic wastes (MPW) normally remain a part of municipal solid
wastes as they are discarded and collected a household wastes. The various sources of
MPW plastics includes domestic items (food containers, milk covers, water bottles,
packaging foam, disposable cups, plates, cutlery, CD and cassette boxes. fridge liners,
vending cups, electronic equipment cases, drainage pipe, carbonated drinks bottles,
plumbing pipes and guttering, flooring. cushioning foams, thermal insulation foams,
surface coatings, etc.), agricultural (mulch films, feed bags, fertilizer bags, and in
temporary tarpaulin-like uses such as covers for hay, silage, etc.), wire and cable,
automobile wrecking, etc. Thus, the MPW collected plastics waste is mixed one with

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

major components of polyethylene, polypropylene, polystyrene, polyvinyl chloride,

polyethylene terephthalate, etc. The percentage of plastics in MPW has increased
significantly.

1.3.2. Industrial Plastic Wastes

Industrial plastic wastes are those arising from the large plastics manufacturing,
processing and packaging industry. The industrial waste plastic mainly constitute plastics
from construction and demolition companies (e.g. polyvinylchloride pipes and fittings,
tiles and sheets) electrical and electronics industries (e.g. switch boxes, cable sheaths,
cassette boxes, TV screens, etc.) and the automotive industries spare-parts for cars, such
as fan blades, seat coverings, battery containers and front grills). Most of the industrial
plastic waste has relatively well physical characteristics i.e. they are sufficiently clean and
free of contamination and are available in fairly large quantities.

Disposal methods of waste plastics & their advantages and

Disadvantages:
OCEAN DUMPING
Advantages: Disadvantages:
 convenient  ocean overburdened
 inexpensive  distruction of food sources
 source of nutrients, shelter and  killing of plankton
breeding  desalination
SANITARY LANDFILL
Advantages: Disadvantages:
 volume can increase with little  completed landfill areas can settle
addition of people/equipment and requires maintenance
 filled land can be reused for other  requires proper planning, design,
community purposes and operation
INCINERATION
Advantages: Disadvantages:
 requires minimum land  expensive to build and operate
 can be operated in any weather  high energy requirement
 produces stable odor-free residue  requires skilled personnel and
 refuse volume is reduced by half continuous maintenance

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

 unsightly - smell, waste, vermin

OPEN DUMPING
Advantages: Disadvantages:
 inexpensive
 Health-hazard - insects, rodents etc.
 damage due to air pollution
 ground water and run-off pollution
RECYCLING
Advantages: Disadvantages:
 key to providing a livable  expensive
environment for the future  some wastes cannot be recycled
 technological push needed
 separation of useful material from
waste difficult
Table 1.2

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 2

PROBLEM STATEMENT
The demand for plastic is increasing day by day which possess a tremendous
threat to the environment. Around 5.6 million tons per annum of plastic waste is
generated in India which is about 15,342 tons per day. In the coming few years the waste
amount will still enlarge to an extent, so there should be ways and means to get rid of
these huge amounts and transform it into useful and highly demands applications. Hence,
by pyrolysis process we can convert waste plastics into fuel.
From the previous projects and reports it was found that external heating was
used. As a result, the heat loss was very high leading to low conversion efficiency. In this
project we are using electric heater as source of heat enclosed in a ceramic blanket
insulator which reduced the heat loss and increased the efficiency.

Fig 2.1(a) Gas is used as heating Purpose Fig 2.1(b) Electric heater is used

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 3
LITERATURE REVIEW
1. Yasha Shukla, Hemant Singh, Shiwangi Sonkar and Deepak Kumar: - The paper
titled “Design of Viable Machine to Convert Waste Plastic into Mixed Oil for
Domestic Purpose” states in the abstract that the aim of the article is to provide a more
efficient design of machine to convert waste plastic into mixed oil for domestic
purpose. In this machine daily domestic waste like polyethene, polypropylene or
normal plastic carrying bag are converted to oil. This machine employs a closed
container (stainless steel), temperature controlling electric heater and layers of
insulating materials, these materials make machine more efficient and safer for use.
For effective pyrolysis process the temperature of mild steel container (full of waste
plastics) is raised by temperature controlling electric heater and for condensation
process, water at room temperature is employed.[1]

2. Md. Akram Hossain, Md. Raquibul Hasan & Md. Rofiqul Islam: - State in their
paper titled “Design, Fabrication and Performance Study of a Biomass Solid Waste
Pyrolysis System for Alternative Liquid Fuel Production” the abstract is presented
here. Now-a-days production of Bio-fuel is a prime concern in the world due to
decrease other fuel source. The conversion of devdaru seeds into pyrolytic oil by fixed
bed reactor has been taken into consideration in this study. A fixed bed pyrolysis
system has been designed and fabricated for obtaining liquid fuel from biomass solid
wastes. The major components of the system are: fixed bed reactor, liquid condenser
and liquid collectors. The devdaru seeds in particle form is pyrolized in an externally
heated 7.6 cm diameter and 46 cm high fixed bed reactor with nitrogen as the carrier
gas. The reactor is heated by means of a cylindrical biomass source heater. Rice husk,
cow dung and charcoal are used as the energy source. The products are oil, char and
gas. The parameters varied are reactor bed temperature, running time and feed particle
size. The parameters are found to influence the product yields significantly. The
maximum liquid yield is 51 wt.% at 500o C for a feed size of 1.18 mm at a gas flow
rate of 5 liter/min with a running time of 90 minute. The pyrolysis oil obtained at
these optimum process conditions are analyzed for some of their properties as an
alternative fuel. We get the higher heating value of devdaru seeds oil is 24.22 MJ/kg.
The heating value of the oil is moderate.[3]

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

3. Harsha Vardhan Reddy T, Aman Srivastava, Vaibhav Anand and Saurabh

Kumar: - Stated in their paper entitled “Fabrication and Analysis of a Mechanical
System to Convert Waste Plastic into Crude Oil” that use of plastics are increasing
day by day. One of the major problems following it is the disposal of waste generated
from plastics. Since plastics are made of crude oil, why can’t it be reverse processed?
i.e., plastics back to crude oil. This is the basic idea behind the paper. Besides helping
to remove a lot of plastic waste generated thus creating a neat and tidy environment. It
also helps to generate fuel which when converted to convenient form can be used as a
source of energy. This combined advantage has inspired us to design and develop a
machine which can efficiently convert plastic to suitable form of fuel. In this paper, a
method is suggested to convert waste plastic to useful fuel. The objective of this is to
develop a machine which converts plastics to some useful form of fuel.[2]

4. S.L. Low, M.A. Connor and G.H. Covey: - The paper titled “Turning mixed plastic
wastes into a useable liquid fuel”, the abstract is presented here. As landfill and
incineration become more expensive and less accepted, the recycling of plastic wastes
is gaining increasing importance. More emphasis is thus being given to new disposal
options, which have high energy recovery values and are more environmentally
attractive. Pyrolysis is one promising method for the treatment of mixed and
contaminated plastic wastes. Plastics are thermally degraded to produce useful liquid
hydrocarbons, which can then either be added to existing fuel or solvent product, or
returned to a refinery where they can be added to the feedstocks. A simple pyrolysis
reactor system is described. Results of pyrolysis tests showed that pure samples of
polyolefinic and polystyrene resin can readily be pyrolysed to produce liquid yields in
excess of 70%. However, liquid yields were affected by heating rates and heat loss
patterns in the reactor system. Further experimental work suggests that when
pyrolysed, mixed plastic wastes behave much like the resins from which they
originate. In light of the results from the experiments, the technical feasibility of
setting up a pyrolysis plant in Victoria to process waste plastics into liquid fuel was
discussed. This study thus forms the ground work needed for the design of a small
pyrolysis plant.[18]

5. Achyut K. Panda, R.K. Singh, D.K. Mishra (et al):- “Thermolysis of waste
plastics to liquid fuel”. In this research projects he used wide range of old and
new technologies for chemical recycling of waste plastic to liquid fuel. [6]

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

6. Tiwari D.C., Ejaz Ahmad, Kumar Singh K.K 2009(et al):- wrote on catalytic
cracking process in which waste plastic is melted and cracked in the absence of
oxygen and at very high temperature, the resulting gases were cooled by condensation
and resulting crude oil was recovered. From this crude oil various products petrol,
diesel and kerosene etc. can be obtained by distillation. [7]

7. Antony Raja and Advaith Murali (et al):- “Conversion of Plastic Wastes into
Fuels”.He concluded that we can convert all types of waste plastic into hydrocarbon
fuel at the temperature profile 350ºC to 500ºC through pyrolysis process. [8]

8. Wenger Jorn.Investigated (et al):- The pyrolysis of waste plastics (HDPE and
polypropylene) in a tubular reactor at 500 °C temperature in the presence and absence
of Y-zeolite catalyst. It was found that the yields of gases, gasoline and light oil could
be increased in the presence of catalyst. [9]

9. Manish Chand Sharma, Neelesh Soni (et al):- Issued a paper in 2013 on
“Production of alternative fuel from waste oil and comparison with fresh diesel”. This
research paper compares the diesel obtained from pyrolysis of plastic oil with
conventional diesel oil. [10]

10. C. Wongkhorsub, N. Chindaprasert (et al):- Published a paper in July 2013 titled
“A Comparison of the Use of Pyrolysis Oils in Diesel Engine”. This research
describes a comparison of the use of pyrolysis oils which are the plastic pyrolysis oil
and diesel oil in the assessment of engine performance, and feasibility analysis.
Pyrolysis oils and waste plastic are studied to apply with one cylinder multipurpose
agriculture diesel engine. Thus, a comparison between the two is studied. [11]

11. Alkazadagaonkar (et al):- The experiments on conversion waste plastic into liquid
fuels using new technology. We can convert all types of waste plastics into liquid
fuels at a temperature of 3500C-500oC.
12. M.fAli:- reported that the high yields of liquid fuels in the boiling range 100°C–
480°C and gases were obtained along with a small amount of heavy oils and insoluble
material such as gums and coke. The results obtained on the co-processing of
polypropylene with coal and petroleum residues are very encouraging as this method

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

appears to be quite feasible to convert plastic materials into liquefied coal products
and to upgrade the petroleum residues and waste plastics.

13. Miskolczi:-Investigated the pyrolysis of real waste plastics (high-density

polyethylene and polypropylene) in a pilot scale horizontal tube reactor at 520 °C
temperature in the presence and absence of ZSM-5 catalyst. It was found that the
yields of gases, gasoline and light oil could be increased in the presence of catalyst.
They also concluded that the plastic wastes could be converted into gasoline and light
oil with yields of 20–48% and 17–36% respectively depending on the used
parameters.

14. A.G. Buekens, H. Huang (et al.):- Catalytic plastics cracking for recovery of
gasoline-range Hydrocarbon liquid fuels municipal plastic wastes, Resources,
Conservations and Recycling.1998

15. F murphy:- from the recent literature, it is evident that the process of converting
waste plastic to reusable oil is a current research topic, preparation of blends of diesel
with varying proportions of waste plastic oil produced from the thermal pyrolysis and
the analysis of viscosity and density of these blends is presented. The feasibility of the
waste plastic oils derived from PVC plastics as an alternate fuel for transportation is
also checked by conducting performance test on a single cylinder Kirlosker diesel
engine equipped with electrical loading at 50% of the engine maximum load i.e., at
3.7 Kw

16. A. Adrados, I. de Marco, B.M. Caballero, A. Lopez, and M. F. Laresgoiti, A.

Torres (et al):- Pyrolysis of plastic packaging waste: A comparison of plastic
residuals from material recovery facilities with simulated plastic waste.

17. A.Lopez (et al):-Pyrolysis of munciple plastic wastes. Influence of raw material
composition under catalytic conditions. Waste management journal home page.

18. Bockhorn H (et al.):-Kinetic study on the thermal degradation or thermal pyrolysis
of plastic wastes. They concluded that, the temperature and reaction time thermal
pyrolysis is slightly greater than the catalytic pyrolysis. [8]

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

3.1 Outcome of literature survey

 We can convert all types of waste plastic into hydrocarbon fuel at the temperature
profile 250ºc to 350ºc by Thermolysis of waste plastics.

 Addition of catalyst enhances the conversion and fuel quality. There is a significant
reduction in the degradation temperature and reaction time under catalytic condition.

 Fuel obtained from pyrolysis process shows nearly same properties as that of diesel
fuel and petrol fuel oil. So we can use plastic oil as alternative fuel.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 4
OBJECTIVES
 To build up the reason for the improvement and execution of waste plastics
reusing with the use of environmentally sound technologies (EST). To advance
asset protection and ozone depleting substances
 To raise awareness in developing countries on plastic waste and its possible reuse
for conversion into diesel or fuel.
 To reduce the dependency on gulf countries for fossil fuels, thereby contributing
to the economic growth of the country.
 To collect the household plastic waste from different places.
 To develop and fabricate the pyrolysis unit to produce liquid fuel from plastic
waste.
 Conversion of household plastic waste in to liquid fuel.
 To purify the produced liquid fuel by water washing method.
 To conduct the different experiments to determine the different properties of
liquid fuel.
 Compare the properties of liquid fuel with diesel fuel.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 5
METHODOLOGY
5.1. PYROLYSIS PROCESS
Pyrolysis is the thermal decomposition of materials at higher temperatures in the
absence of oxygen (or an inert atmosphere).It is a chemical reaction process which
involves molecular breakdown of larger molecules into smaller molecules in the presence
of heat. It includes the difference in concoction arrangement and the procedure is
irreversible. The word pyrolysis is begat from the Greek-determined components pyro
which signifies "fire" and lysis which signifies "isolating".

The most common application of pyrolysis is applied to the treatment

of organic materials. It is one of the processes involved in charring wood, starting at
temperature range of 250oC–350°C. During pyrolysis of organic substances, it produces
volatile products and leaves a solid residue which is rich in carbon, char. Extreme
pyrolysis leaves mostly carbon as the residue which is called carbonization.

Pyrolysis process finds a heavy application in the chemical industry as well. For instance,
it is utilized to deliver ethylene, numerous types of carbon, and different chemicals from
oil, coal, to create coke from coal.. Aspirational applications of pyrolysis would be to
convert waste plastics back into usable oil, or waste into safely disposable substances.

Pyrolysis varies from other high temperature forms like ignition and hydrolysis .It as a
rule does not include the expansion of different reagents, for example, oxygen (O2, in
burning) or water (in hydrolysis).However, in practice, it is often not practical to achieve
a completely oxygen or water-free conditions, because some amount of oxygen is always
present which cause oxidation.

Fig 5.1 Breaking of hydrocarbon chain in pyrolysis process

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

5.2. PYROLYSIS OF PLASTIC

Production of fuel from waste plastic involves pyrolysis process. In this process,
plastic is rapidly heated to 250o-350°C in a reactor in the absence of oxygen. The
temperature required depends on the types of plastics used. Once the melting point is
reached, the plastics melts and the vapour rise up and is collected in the condensing unit.
Water is used to condense the vapour. The condensed vapour is collected above the water
due to the density difference of the oil and water. Finally, the oil is poured out of the
condensing unit through the tap provided. The pyrolysis of plastic gives out the mixture
of fuel, gases and solid char. Variation of the pyrolysis process, type of plastic used and
the temperature will produce the varying percentage of these three products.

Various technologies and methodologies can be used for the pyrolysis process
such as batch reactor, semi batch reactor, fluidised bed reactor, fixed bed reactor etc. The
process can be performed with or without the use of catalyst. The different types of
catalyst that can be used for plastic pyrolysis are zeolite, alumina (Al2O3), silica (SiO2),
etc.

5.3 STEPS INVOLVED IN PROCESS

Collection and Heating

Feeding
segregation of
into
plastic
reactor

Distillation Liquid
Condensing
collection

Testing

Fig 5.2 Flow diagram of Process

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

5.3.1. COLLECTION AND SEGREGATION OF PLASTIC

Fig 5.3 Collection of plastic

The plastic waste is collected from different sources such as household, hotels,
market etc. and separated on the basis of their types. The various types of waste plastic
include food containers, milk covers, water bottles, packaging foams, disposable cups and
plates, broken plastic chair, shopping bags etc. The plastics can be separated as PET,
HDPE, LDPE, polypropylene, etc. After the separation, plastic is cleaned to remove any
impurities like dust, dirt, with the help of soap water. The plastic is then dried in the sun
to remove the moisture present and cut into small pieces of size less than 5cm.

5.3.2. FEEDING INTO REACTOR

Once the waste plastic is cut into small pieces, the next step is feeding into the
reactor. The reactor is made from mild steel. The flange is opened and plastic pieces are
fed into the reactor and the flange is closed again. It is necessary to prevent any leakage in
the reactor. Hence, gasket is provided for that. However, gasket should be able to subtend
high temperature else it will burn out.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Fig 5.4 Plastic feeding into reactor

5.3.3. HEATING

An electric heater which has capacity of 3KW is used to heat the reactor. A
Nichrome coil is used as heating element and power supply is 230V, 50Hz AC. A
temperature indicator and controller are used to record and maintain the required
temperature. The heater can increase the temperature up to 200°C within 15 minutes and
the temperature indicator and controller can record temperature up to maximum of
1200°C.

Fig 5.5 Heating element

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

5.3.4. CONDENSING

The plastic waste gets evaporated at temperature 250-350°C. This vapour is condensed to
atmospheric temperature by using tube condenser.

Fig 5.6 Condensing process

5.3.5. LIQUID COLLECTION

The vapour coming out of condenser is condensed and collected at the liquid
collector. The liquid collector is basically a small tank filled with 3/4th water. The
condensed fuel is collected above the water due to the difference in the density of oil and
water. Once the oil stops coming from the condenser, the oil is collected. Two taps are
provided at different heights, one for fuel collection and another for draining water out.

Fig5.7 liquid collector

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

5.3.6. DISTILLATION

Once the fuel is collected, the oil is distilled to increase purity. For this, a sample
of oil (about 250ml) is taken in a round bottom flask and heated to about 70°C. The oil
starts to boil and the vapour is condensed and collected in a separate flask. Water is
supplied for condensing the process. Thus, fuel with better property is achieved.

Fig5.8 distillation process

5.3.7. TESTING

The oil sample is finally taken to laboratories for testing its properties like density,
calorific value, flash point, fire point, viscosity, etc. The test is carried out for different
samples before coming to final result.

Fig 5.9 Oil Sample

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 6

EXPERIMENTAL SETUP

6.1 Introduction

All the experimental setup and instruments used in this process will be discussed
in this section. The procedure followed to convert plastic into oil. All the setup are
mentioned in the order of one after another.

6.2 Working of Pyrolysis Process

Water

Reactor
@250oC
Condenser Separator
-3500C
Waste
Plastic
pieces

Liquide Fuel
Residue

Fig 6.1 Block Diagram of pyrolysis process

Plastic was cut into a number of small pieces. The plastic chips were washed,
dried, and fed into a pyrolysis reactor unit. The pyrolysis reactor used in this process was
in cylindrical chamber. The reactor was placed inside the electric heater. The heater has a
capacity of 3Kw which is insulated by glass wool. By means of high temperature outside
the reactor vacuum was crated inside of reactor. Inside the heater there is a sensor which
is connected whit temperature controller which control the temperature outside the

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

reactor. The process was carried out between the temperature ranges of 250oC-350oC
outside of reactor for 1 hours and 30 minutes. The products of pyrolysis is in the form of
vapour were send to a water cooled condenser and the condensed liquid was collected as
a fuel. The figure 6.2 shows the Experimental setup of the process. Fuel collected was in
crude form.

Fig 6.2 Experimental setup

6.3 Design Details

6.3.1. Reactor

Material- Mild steel

Outer diameter- 140mm

Inner diameter-137mm

Height- 420mm

Thickness-3mm

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Flange outer diameter- 252mm

Flange inner diameter- 140mm

Design Calculation Of reactor

Input
2
Internal Design Pressure, P=8 bar (8*103425 N/m )
Internal Radius, r = 67mm
Allowable Stress, S = 70 MPa @ 300°c
Weld Joint Efficiency, E = 70% for butt joints
Calculation
Thickness of Reactor Shell, t = (P*r)/(S*E-. 6*P)
8×103425×.067
=
70×106 ×.7−.6×8×103425
Output
t = 1.14mm. Considering the safety factor, the calculated thickness of reactor shell has
been increased to 3mm. t = 3 mm

Fig 6.3 Reactor unit

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Reactor is made of mild steel material with flange at the top end. Asbestos gasket
is provided in between of flange to make leak proof. Reactor and flange has a same size
hole where bolt and nut is fitted to close the reactor chamber. Reactor is kept inside of
heater. Reactor is heated externally by means of high temperature inside of heater. The
pyrolysis is simple process in which plastic is melted at high temperature about 250oC-
350oC in the absence of oxygen. Due to thermal cracking of plastic substance is obtained
and finally the end products will form in the form of oil.

6.3.2. Condenser Tank

Material-Plastic

Tank capacity- 8 ltr

No. of tap-2

Fig 6.4 Condenser tank

Condenser is made up of plastic material with 2 taps to remove water and oil from
the tank. After heating the plastic in the reactor the gas is allowed to escape through the
outlet. Condenser pipe is dipped into the water containing jar so as to condense the
vapour to collect the fuel drop by drop from outlet of the condense tank.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

6.3.3. CAD model of setup

Fig 6.5 CAD Assembled view of setup

6.3.4. Heater

Material of coil-Nichrome (Ni-80%, Cr-20%)

Power- 3Kw

Size-150*150mm

Height-300mm

Input supply-230V, 50Hz

Heater is used to heat the reactor for pyrolysis process. Heater coil is made up of
Nichrome wire (Ni-80%, Cr-20%) which has the power capacity of 3Kw. It requires
230V input supply. Heater is insulated with glass wool to reduce the heat loses from the
heater. Heater is connected with the temperature controller. Which control the
temperature of the heater. Sensor is used to sense the temperature of the heater which is
connected to controller.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Fig 6.6 Heater

6.3.5. Controller and indicator

Fig 6.7 Temperature controller and Indicator

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Controller is the device which is used to control the temperature of the heater and
also supply the power to the heater. It has the capacity to control the temperature up to
10000C. The regular working temperature range is 250oC-350oC. MCB is used in
controller for safety purpose. If there is any short-circuit or over load then the MCB will
full down. Due to which power circuit will break and there is not any power supply
toward the heater.

6.3.6. Sensor

Fig 6.8 Sensor

Sensor is the device which is used to sense the temperature of the heater. This is K
type thermocouple. Its one end is kept into the heater and other end is connected to the
controller. It can sense the temperatures up to 800oC.

6.4 Distillation setup

The plastic fuel so obtained is further distilled to improve the purity of the fuel.
The experimental setup is as shown in the above figure 6.9. About 250ml of fuel is
poured in a round bottom flask and mounted on a heater. The temperature of heater is
maintained at around 70 degree Celsius with the help of thermostat. Water in and water
out is provided for condensation. Once the fuel starts to boil, the evaporated vapour is
passed through condenser and collected in a flask in a pure form with improved
properties.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Fig 6.9 Distillation process setup

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 7

PROPERTIES OF FUEL
Density: It is defined as mass per unit volume. It is given as

Mass
Density =
Volume

Its SI unit is kg/m3

Calorific value: Calorific value is defined as the amount of energy released by the
complete combustion of a material or fuel in the presence of oxygen. Its Si unit is kJ/kg or
kcal/kg. It is given by formula
heat generated
Calorific value = mass flow rate

Viscosity: It is defined as the resistance offered by the fluid for the flow of fluid over
another layer when they are in motion relative to each other.

Flash point: It is the minimum temperature at which fuel produces sufficient vapour to
produce a flash when a flame is brought near it.

Fire point: It is the minimum temperature at which fuel produces sufficient vapour such
that it continues to burn at least for 5 seconds when a flame is brought near it.

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CHAPTER 8

RESULTS AND DISCUSSION

Flash Point: - Plastic liquid fuel is poured into the flash point apparatus up to the line
marked in the apparatus. Then the oil is heated and check the temperature at regular
interval. The outside fire is introduce till the flash is obtained. Once the flash is obtained
the reading is noted down. Flash point is obtained at temperature 28oC.

Fire point: - After recorded the flash point continuous give the external fire until the fire
point obtained. Once the fire point obtained the temperature is recorded. At 32oC
temperature the fire point is obtained.

Fig8.1 Cleveland apparatus

Density: - Density of fuel at different temperature was measured by a standard 50ml

flask.

Weight of the empty 50ml flask (W1) = 39gm

Weight of the flask with oil (W2) = 77gm

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

Weight of the oil (W) = W2-W1 = 77-39 = 38 gm

Weight of oil
Density of oil (ρ) =
volume of oil

38×1000
=
50

= 760 Kg/m3

Fig 8.2 Redwood viscometer

Kinematic Viscosity (γ):- Viscosity is an important property of fuel. It is fluid’s

resistance to the flow at a given temperature.

Procedure for calculation of viscosity:

1. First clean the viscometer cup with suitable solvent.

2. Level the viscometer with leveling screw.
3. Fill the outer portion with water to fine the temperature.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

4. Place the ball to close the valve at the bottom of the viscometer.
5. Pour the oil to be tasted.
6. Place the flask at the bottom of the viscometer.
7. Insert the thermometer on the top to take the temperature.
8. Heat the water filled in the bath.
9. Lift the ball to flow the oil
10. Stop the stop watch when the oil reaches the 50 ml mark on the flask.
11. Record the time taken for 50ml of oil flow into the flask.
12. Calculate the viscosity of the fuel.

188
(γ) = (0.26 × 𝑡 − ) × 10−6
𝑡

Where t = Time taken for collection of ml oil in seconds = 31 sec

188
γ= (0.26 × 31 − ) × 10−6
31

= 1.99× 10−6 m2/s

Calorific value: - Calorific value of fuel is the quantity of heat produced by its
combustion at constant pressure and under normal condition. The calorific value of
plastic pyrolysis is 47532.740326 kJ/kg

Expected Outcome of pyrolysis plant

Particulars Test 1 Test 2 Test 3

Mass of 600gm 800gm 1000gm

plastics used

Total oil 520ml 720ml 890ml

production
Total char 75gm 76gm 105gm
production
Electric power 3kWh 3kWh 3kWh
supply
Time of 1hr 30min 1hr 25min 1hr 30min
operation
Table 8.1

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 9

ECONOMY OF THE FUEL PRODUCTION

Cost of 1Kg plastic = Rs 5
Time taken =1.5 hrs.
Power supplied = 3Kw
Cost of 3Kw of power supplied for 1 hours = Rs 15
So that, cost of 3Kw of power supplied for 1.5 hours = Rs 22.5
Cost of product for producing of 1 ltr = Rs (5+22.5) = Rs 27.5
Market price of plastic oil = Rs 48 per ltr

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 10

COMPARISION OF PROPERTIES OF PLASTIC

WITH DIESEL AND PETROL

SI. NO. Properties Plastic Oil Petrol Diesel

1 Density 760 740 832

(Kg/m3)

2 Calorific value 47528.55 45800 45500

(KJ/Kg)

3 Kinematic 1.99× 10−6 2.1× 10−6 2.5 × 10−6

viscosity (m2/s)
@ 40o C
4 Flash Point 28 29 48
(o C)
5 Fire Point 32 33 55
(o C)

Table 10.1

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 11

ADVANTAGES AND LIMITATIONS

11.1 Advantage
1. The waste plastic is converted in fuels having high calorific value.

2. It solves the problem of disposal and management of waste plastic by converting

then into alternative source of energy.

3. Burning of plastic produces toxic gases like nitrogen dioxide, sulphur oxides,
dioxins and other harmful gases. Plastic pyrolysis process produces minimum
hazardous gases. Hence, the process helps to control environmental pollution.

4. The process is environment friendly.

5. It promotes environmental protection. When people realise that waste plastic can
be converted into fuel they won’t dump plastic unnecessarily.

6. Plastic fuel can act as an alternate fuel to diesel, petrol, kerosene, etc.

7. Plastic fuel can be used as good source of heat in sugar industry, brick industry,
and steel industry.

8. Plastic pyrolysis fuel is cheaper than other fuels.

9. The plastic fuel can help in reducing the dependency on gulf countries for
petroleum.

11.2 LIMITATIONS

1. Plastic pyrolysis fuel cannot use directly in engine.

2. Initial cost of machine is high.

3. Fractional distillation process is complicated.

4. Identification of type of plastic is difficult.

5. The process is time consuming.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 12

APPLICATION OF PROJECT & FUTURE WORK

1. It can be used as alternate source of fuel in diesel engines.

2. It can be used as a fuel in diesel generators.

3. It can be used for heating in sugar industry, steel industry, etc.

4. It can be used for heating boilers.

5. The application of this project could help in reducing the dependency on the gulf
countries and promote a step towards innovation.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

CHAPTER 13

CONCLUSION
Plastic bears a major threat to the current scenario and the environment. Millions of
tonnes of plastics are produced on the daily basis and only few percentage of the waste
plastic are being successfully recycled. Since, plastic takes long years to decompose,
some alternative to plastic should be developed. Also, the world is facing the problem of
shortage of petroleum.

Therefore, conversion of waste plastic into fuel can provide a better solution to the
disposal problem of waste plastic as well as act as an alternative to fossil fuel. From the
experiments and trials, we also found that by using pyrolysis method we were able to get
recover 80-85% oil for polypropylene plastic (Type-5). However, the output varies
depending on the type of plastic used. Also, the plastic fuel showed properties similar to
that of diesel fuel.

Hence, we can conclude that pyrolysis of plastic into fuel can solve both the
problem of plastic waste management as well as shortage of fossil fuel if plant is set up at
the commercial level.

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

BILL OF MATERIAL
Description Quantity Rate Amount
Rs.
Temperature 1 5200 5200
indicator and
controller
Ceramic Blanket 2 Roll 1575 per roll 3150
Heater coil 1 3300 3300
(3Kw)
Sensor 1 750 750
R B Flask 1 342 342
L BEND tube 1 206 206
Wire 20m 19 per meter 380
Power board 1 120 120
Switch 1 40 40

Tape 1 25 25

Plug 1 60 60
Reactor with 1 3000 3000
flange
Condensing pipe 1 250 250
(full set)
Total 16,823

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Design and fabrication of machine to convert plastic into oil and gaseous fuel production

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