GMR Mechanical Dept generates fuel from plastic waste

DepartmentofMechanical
Engineering Humility Entrepreneurship Teamwork
Learning Social Responsibility Respect for IndividualDeliver The Promise
GMRInstituteofTechnology,
Rajam
Dept. of Mechanical engineering
GMR Institute of Technology
An Autonomous Institute Affiliated to JNTUK, Kakinada
Final Review
9/05/2020
BATCH NO:11

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BIOFUEL FROM PLASTIC WASTE
Presented by batch-11
K.Gowtham K.Raviteja K.Revati pathi
17341A0346 17341A0356 17341A0359
T. Naveen Deepak P.Manikantha
18345A0307 18345A0312
Under the Guidance of
Dr.A.Avinash
Assistant Professor
Dept. of Mechanical Engineering

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I.Introduction
1.Thermosetting plastics
2.Thermoplastics
II.Plastic Waste Management
1.Thermo-catalytic degradation of plastic waste
A.Catalytic cracking
B.Non Catalytic cracking
- Gasification
- Pyrolysis
III.Pyrolysis
1.Apparatus
2.Description
3.Process
4.Properties of the Fuel
5.Experminetal setup of IC engine
6.Specification of IC engine
7.Performance Analysis
IV.Results and Discussions
V.Conclusion
VI.Literature review
VII. References
CONTENTS-

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Plastics have woven their way into our daily lives and now pose a
tremendous threat to the environment. Over a 100 million tonnes of plastics
are produced annually worldwide, and the used products have become a
common feature at over flowing bins and landfills. Though work has been
done to make futuristic biodegradable plastics, there have not been many
conclusive steps towards cleaning up the existing problem. Here, the
process of converting waste plastic into value added fuels is explained as a
viable solution for recycling of plastics. In this study, plastic wastes (High
density polyethylene) were used for the pyrolysis to get fuel oil that has the
same physical properties as the fuels like petrol, diesel etc. Pyrolysis runs
without oxygen and in high temperature of about 300°C.Converting waste
plastics into fuel hold great promise for both the environmental and economic
scenarios.
ABSTRACT

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I.INTRODUCTION
• Every year humans produce nearly 280 million tons of plastic and much of
that plastic ends up in the environment, harming marine life and other
ecosystems.
• Also the plastic wastes are dumped in the oceans threatening the health
and safety of marine life. The uncontrolled incineration of plastic produces
polychlorinated dibenzo-p-dioxins and carcinogen. So converting the waste
plastic into crude oil will have two benefits.
• First of all, the hazards caused due to plastic waste can be reduced and
secondly, we will be able to obtain some amount of oil from it, which can be
further purified to be used as a fuel in different areas such as domestic fuel,
fuel for automobiles and industries etc.

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II. PLASTICS
• Plastics are synthetic organic materials produced by polymerization. They are
typically of high molecular mass, and may contain other substances besides
polymers to improve performance and/or reduce costs.
• Plastics are typically organic polymers of high molecular mass and often
contain other substances. They are usually synthetic, most commonly derived
from petrochemicals.
• They have prevailed over traditional materials, such as wood, stone, horn and
bone, leather, metal, glass, and ceramic, in some products previously left to
natural materials.
• In developed economies, about a third of plastic is used in packaging and
roughly the same in buildings in applications such as piping, plumbing or vinyl
siding.

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1.Thermosetting Plastics
• Thermosetting plastics are generally stronger than thermoplastic materials
due to the three-dimensional network of bonds (crosslinking).
• They are better suited to high-temperature applications. The higher the
crosslink density and aromatic content of a thermoset polymer, the higher the
resistance to heat degradation and chemical attack.
• Mechanical strength and hardness also improve with crosslink density,
although at the expense of brittleness. Thermosetting can melt and take
shape only once.
• They are not suitable for repeated heat treatments and therefore after they
have solidified, they remain solid.

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2.Thermo Plastics
• Thermoplastics can repeatedly soften and melt if enough heat is applied and
hardened on cooling, so that they can be made into new plastics products.
Examples are polyethylene, polystyrene and polyvinyl chloride, among
others.
• Plastics are classified into two types. They are High-density polyethylene
and Low-density polyethylene.
A. Low-Density Polyethylene
• Low-density polyethylene (LDPE) is used for its toughness, flexibility, and
relative transparency. LDPE is used to make bottles that require extra
flexibility.
• To take advantage of its strength and toughness, it is used to produce
grocery bags and garbage bags, squeezable bottles, shrink wrap, stretch
films, and coating for milk cartons.

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B.High-Density Polyethylene
• Polypropylene and polystyrene plastics are the types of HDPE plastics
and is known for it's big strength-to-density ratio.
• Polypropylene (PP) is known for its high melting point, which makes it ideal
for holding hot liquids that cool in the bottles (for example, ketchup and
syrup).
• Some important groups in these classifications are the acrylics, polyesters,
silicones, polyurethanes, and halogenated plastics.
• With a melting point more than 20 °C (36 °F) higher than LDPE, it can
withstand repeated exposure to 120 °C (250 °F) so that it can be sterilized.
• The recycling rate of HDPE bottles and jars was 29.1 percent in 2017, and
the rate for HDPE natural bottles was 31.2 percent in 2017.

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II. PLASTIC WASTE MANAGEMENT
Figure 1: Waste to Energy Technology

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• The conversion of waste matter to energy carriers can be achieved through
biochemical, thermo-chemical and mechanical routes.
• In Gasification, the product gas can be used in Combined Heat and
Power(CPH) generation or as transportation fuel in special vehicles or it can
be processed further to liquid transportation fuels.
• Combustion is an ancient and very common technology for CHP production
and suitable for the energy recovery from a wide range of mixed solid waste
• Pyrolysis is expected to be commercial technology in large scale, but there
are challenges. The product, pyrolysis oil, is demanding to upgrade to the
quality of transport fuel.
Waste to Energy Technology

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1.Thermo-Catalytic Degradation Of Plastic Waste
• The catalytic cracking, non-catalytic cracking (i.e. thermolysis: pyrolysis,
gasification and hydrogenation), steam degradation, etc. are under industrial
applications to produce energy from waste plastic polymers.
• Mixture of heterogeneous(pyrolysis) and contaminated polymers without a
pre-treatment(gasification) can be treated in these processes.
• Moreover, since waste plastics are valuable sources of various chemical
compounds, and liquid and gas fuels, both the thermal and catalytic cracking
of waste plastics are considered one of the most feasible large-scale
recycling methods to produce those compounds.
• Organic compounds either biodegradable or non-biodegradable lead to the
energy as the output of thermochemical processes.

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A. Catalytic cracking
• Catalytic cracking is widely used in the petroleum refining industry to
convert heavy oils into more valuable gasoline and lighter products.
• As the demand for higher octane gasoline has increased, catalytic cracking
has replaced thermal cracking.
• Addition of catalyst enhances-
1) Significantly lowers Pyrolysis temperatures and time.
2)A significant reduction in the degradation temperature and reaction time.
3)It results an increase in the conversion rates for a wide range of polymers.
4)Increases the gaseous product yields.

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B. Non Catalytic cracking
1.Gasification
• Gasification is conversion of solid waste biomass/MSW to combustible gas
such as hydrogen, synthetic fuels and carbon monoxide, hydrogen and
carbon dioxide -at elevated temperature (500-1800 deg C).
• During the process, MSW is segregated in this process to remove non
combustible materials.
• The purpose of gasification of waste is to minimize emissions and to
maximize the gain and quality of recyclable products.
• The wastewater generated is also normally produced and treated before it is
discharged to the sewage system for complying the water specifications as
per standard norms.

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• Pyrolysis is generally defined as the controlled heating of a material in the
absence of oxygen.
• In plastics Pyrolysis, the macromolecular structures of polymers are broken
down into smaller molecules or oligomers and sometimes monomer units.
• Further degradation of these subsequent molecules depends on a number
of different conditions including temperature, residence time, presence of
catalysts and other process conditions carbonaceous matter gradually
develops as a deposit on the inner surface of the reactor.
• The Pyrolysis reaction can be carried out with or without the presence of
catalyst and the reactions will be thermal and catalytic Pyrolysis.
2.Pyrolysis

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III. PYROLYSIS
• Pyrolysis is a process of decomposing material by heating in absence of
oxygen generating gaseous and liquids products which can be utilized as
fuels.
• This process can be thermal or catalytic and is an alternative that allows the
conversion of polymers into gas and liquid hydrocarbons. The plastic waste is
processed to produce petrochemical compounds.
• The pyrolysis of plastics yields on average 45-50% of liquid fuel, 35-40% of
gasses and 10-20% of char, depending on the pyrolysis technology.
• Plastic waste mainly consists of polyethylene terephthalate (PET), high-
density polyethylene (HDPE), polyvinyl chloride (PVC), low density
polyethylene (LDPE), polypropylene (PP) and polystyrene (PS).

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1.Apparatus
1.Simple Distillation Heater
2.Round Bottom Flask
3.Condenser
4.Thermometer
5.Collecting tank

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2.Description
• By weight 50% of each HDPE and polypropylene was selected for the
experiment and both waste plastic are solid hard form.
• A round bottom flask (Borosilicate) of 500ml capacity is used in this process.
It is a type of a glass with silica and boron trioxide as the main glass-forming
constituents.
• The reactor is placed under the Heating mantle for external heating with the
raw material inside. The reactor is heated to a temperature of about 450°C
and more.
• Oxygen contained in the flask must be removed in order to reduce the
combustion of plastic inside the reactor. Oxygen is removed by filling the
flask with inert gas (nitrogen) and closed air tight. Condenser cools the entire
heated vapour coming out of the reactor.
• It has an inlet and an outlet for cold water to run through its outer area. This
is used for cooling of the vapour. The gaseous hydrocarbons at a
temperature of about 350°C are condensed to about 30 – 35°C.

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Figure 2: Pyrolysis Distillation Equipment

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3.Process
• Collected waste plastic are cleaned by using liquid soap and water and are
cut into 35 cm size to fit into the reactor conservatively.
• For experimental purpose we used 300, sample 300gm of plastic waste.
The plastic starts melting from 70° C.
• When temperature is increased to 270° C liquid slurry turns into vapour
and the vapour then passes through a condenser fuel is collected and then
when raised to 325 ͦ C.
• The next 40% is collected and finally when held at 400º C the yield is fully
completed.
• During the thermal cracking process plastic portions are not broken down
immediately because plastics have short chain hydrocarbon to long chain
hydrocarbon.
• When temperature profile is increased the plastic carbon-carbon bond
breakdown slowly.
• During in this thermal cracking process some light gas such as methane,
ethane, propane and butane are produced and a separate collecting tank is
used to collect the light gases.

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4.Properties of the Fuel
i)Viscosity
Viscosity varies with feedstock, pyrolysis conditions, temperature, and other
variables. The higher the viscosity, the higher the fuel consumption, engine
temperature, and load on the engine. If the viscosity of oil is too high,
excessive friction may take place.
ii)Density
Density is an important property of a fuel oil. If the density of fuel is high, the
fuel consumption will be less. The oil with low density will consume more fuel
which may cause damage to the engine. Therefore, too low or too high density
of fuel oil is not desirable. So the conventional fuel such as diesel oil, kerosene
oil, and gas oil may be replaced by plastic pyrolysis oil. The physical properties
of the PPO obtained shows a lower density of 0.734g/cm3 compared to diesel
whereas lies in the range of gasoline . The density of PPO increases with an
increase in process temperature while a decrease in volume at a lower
temperature was reported by several researchers.

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iii)Flash Point
Flash point is the lowest temperature at which it can vaporize to form an
ignitable mixture in air. Flash point is used to characterize the fire hazards of
fuels. A low flash point indicates the presence of highly volatile materials in
the fuel that is a serious safety concern in handling and transporting. The
flash point of furnace oil, diesel, and kerosene is higher than WPPO which
indicates that these are easy to handle. By removing lighter components
(such as naphtha/gasoline) the flash point of WPPO will be increased.
iv)Fire Point
The fire point of a fuel is the temperature at which it will continue to burn for at
least 5 seconds after ignition by an open flame. The fire point is used to
assess the risk of the materials ability to support combustion. Generally,
the fire point of any liquid oil is considered to be about (5–10) °C higher than
the flash point. The fire point of waste plastic pyrolysis oil was 20°C.

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v)Pour Point
The pour point is the temperature at which the oil will just ceases to flow when
cooled at a standard rate in a standard apparatus. Pour point determines the
suitability of oil for low temperature installations. (pour point<−15°C). The low
pour point value of WPPO indicates that it is not suitable in cold weather
country. The pour and cloud point are lower than the values of diesel which
shows that it can be used in cold climate regions.
vi)Calorific Value
One of the important properties of a fuel on which its efficiency is judged is its
calorific value. The calorific value is defined as the energy given out when unit
mass of fuel is burned completely in sufficient air. The calorific value of WPPO
was 9829.3515 kcal/kg.
vii)Boiling Point
The boiling point ranges from 58°C to 278°C while there is a minimal
amount of condensate was observed. These condensed particles can be
removed via simple centrifugal treatment.
.

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6.Experimental Setup of IC Engine
• The engine performance tests were conducted with an eddy current
dynamometer, water cooled with loading unit’s research engine setup.
• The tests are performed with a constant speed of 1750 rpm with varying
load from zero to 15kg for diesel and different PPO blends.
• The experimental data was collected twice for reproducibility and found
within±4.8%.
• The parameters like SFC, BTE, volumetric efficiency, and exhaust
temperature were reported with variation in load at different blend ratios.
• All the values/calculations reported were obtained from engine performance
analysis software (Engine Soft) interfaced with test engine setup.

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7.Specifications of an IC Engine
Engine Type : Single cylinder, 4S, Diesel Engine
Engine model : Kirloskar model
Rated power : 5.2kW,7 BHP
Compression ratio : 17.5:1
Injection pressure : 215 bar
Engine rated speed :1500rpm

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Figure 3: Experimental Setup of an IC Engine

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8.Performance Analysis of an IC Engine
i)Load vs. brake thermal efficiency
• The variation in brake thermal
power for diesel and Plastic
Pyrolysis oil(PPO) blends at
different loads is presented in
figure.
• The results show minimal
variation in the BTE when PPO
is mixed with various
proportions. It was observed
that with an increase in PPO
fraction in blends reduces the
BTE with a very slight variation
0
5
10
15
20
25
30
35
40
2 4 6 8 10 12 14 16
BrakeThermalEfficiency(%)
Load (kg)
D/PO : 50/50 D/PO : 100/00
at the reduced loads while the increase in load represents significant variation
in BTE .
• At full load the BTE for diesel is 30.01% while for blends is 29.88%,
31.61%, 31.29%, 31.27%, and 31.22% for 50%.

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ii) Load vs specific fuel consumption
• With an increase in the load,
the SFC for different blends is
represented in figure.
• It was observed that with an
increase in load the SFC
reduces while with blends the
SFC reduces comparatively.
• For diesel, the SFC value is
7.47kg/kWh at zero loads while
at full load the value reduces to
0.274kg/kWh. The value for
50% blend is 0.272kg/kWh.
• At higher engine speed the fuel combustion is improved due to improved
mixing of fuel and air while at higher loads the improved fuel atomization,
better mixing, and high-in-cylinder temperature also promote the combustion
process providing low specific fuel consumption.
0
2
4
6
8
10
12
14
16
18
2 4 6 8 10 12 14 16
Specificfuelconsumption(kg/KWh)
Load (kg)
D/PO : 50/50 D/PO : 100/00

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iii)Load vs Volumetric Efficiency
• With an increase in load, the
volumetric efficiency decreases
for diesel fuel from 80.09% at
zero load to 78.23% at full load.
• The addition of PPO with diesel
increases fuel consumption
with a decrease in volume
efficiency and increase in load
results in increased cut off ratio
which results in reduced
volume efficiency.
• At low blends of 10 and 20% at full load, the volume efficiency is
equivalent to diesel fuel whereas with an increase in ratio to 50% a
decrease in volume efficiency to 77.71% is reported.
• High consumption of fuel is observed due to the lower calorific value of PPO
to generate a high amount of heat and pressure to run the engine which in
turn reduces the volume efficiency for blends as well as for high load.
76.5
77
77.5
78
78.5
79
79.5
80
2 4 6 8 10 12 14 16
volumetricEfficiency(%)
Load(kg)
D/PO : 50/50 D/PO : 100/00

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IV. RESULTS AND DISCUSSIONS
The oxygen is 5.19% in the ultimate analysis of waste HDPE. The oxygen in
the waste HDPE sample may not be due to the fillers but rather to other
ingredients that are added to the resin in the manufacturing of HDPE. Calorific
value of waste HDPE was 45.78 MJ/kg. From the comparison of waste HDPE
with mixed plastic waste, it was found that the carbon and hydrogen
percentage and gross calorific value (GCV) are more in waste HDPE as
compared to mixed plastic. The Al2O3, MgO, CaO and K2O contents in the
acid treated kaolin clay decreased progressively after nitric acid treatment of
pure kaolin clay. From the environmental aspect, the CO2 emission has to be
reduced which adds to the greenhouse effect represents the emission of CO2
with variation in load for diesel and PPO blends at different ratios. It was
observed that the CO2 emission is lower in case of diesel oil due to in
efficient combustion while blends produced an increased CO2 emission due to
increased combustion.

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V.CONCLUSION
Plastics present a major threat to today's society and environment. Over 14
million tons of plastics are dumped into the oceans annually, killing about
1,000,000 species of oceanic life. In this regard, the catalytic Pyrolysis studied
here presents an efficient, clean and very effective means of removing the
debris that we have left behind over the last several decades. By converting
plastics to fuel, we solve two issues, one of the large plastic seas, and the
other of the fuel shortage. By taking into account the financial benefits of such
a project, it would be a great boon to our economy. Recycling is a method
preventing accumulation the excessive waste quantity through their second
processing and utilization in the production process of new materials.
Nowadays it is considered as a method developing the most spectrum of the
environmental protection. Plastic wastes can recycle into valuable gas and
liquid fuels by the through chemical recycling methods such as Hydrogenation,
Chemical depolymerization, Gasification, Thermal cracking, Catalytic
conversions.

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VI.Literature review
S.
No
Title Author Journal
Name
Contents
1 Fuel from Plastic Waste Vijaykumar B.
Chana shetty
and B.M. Patil
International
Journal on
Emerging
Technologies
www.research
trend.net
• Smooth feeding to conversion
equipment.
• Effective conversion into fuel
products.
• Classification of Plastics.
• Methodology(Pyrolysis).
• Solid fuel production.
2 Production of liquid fuel from
plastic waste using integrated
pyrolysis method
Ramli Thahir,
Ali Altway,
Sri Rachmania
Juliastuti and
Susianto
Energy
Reports
• Materials and Apparatus.
• Thermal Cracking Pyrolysis.
• Properties of oil like density, dynamic
viscosity, ash content , calorific value,
octane and cetane number.
3 Performance and emission
analysis of blends of waste
plastic oil obtained by
catalytic pyrolysis of waste
HDPE
Sachiin Kumar,
R.Prakash,
S.Murugan
and
R.K.Singh
Energy
conversion
and
Management
• Characterization of Raw materials
and preparation of Catalysts.
• Preparation of Waste Plastic Oil.
• Experimental setup of CI Engine and
test detail.

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• Wong,S.L.Ngadi,N.Abdullah,I.M.Current state and future “Prospects of plastic waste
as source of fuel”. Renew. Sustain. Energy Rev. 2015, 50, 1167–1180.
• Kalargaris I. The utilisation of oils produced from plastic waste at different
pyrolysis temperatures in a DI diesel engine. Energy 2017, 131, 179–185.
• D.Almeida and M.D.F.Marques,"Thermal and catalytic pyrolysis of plastic waste".
• "Status Of Implementation Of Plastic Waste Management," Government of India,
2015.
• N.D.L.Rao,J.L.Jayanthi and D.Kamalakar,"Conversion Of Waste Plastics Into
Alternative Fuel," International Journal Of Engineering Sciences & Research
Technology, pp. 195-201, 2015.
• A.K.N and N.Sindhu,"Microwave Assisted Pyrolysis of Plastic Waste,“ in Global
Colloquium in Recent Advancement an Muhammad, J. A. Onwudili and P. Williams,
"Catalytic Pyrolysis of waste plastic from electrical and electronic equipment," Journal
of Analytical and Applied Pyrolysis, 2015.
• Effectual Researches in Engineering, Science and Technology (RAEREST 2016) ,
2016.
• H, Robert .D and Edward. “K, Plastics recycling: challenges and opportunities,”
2011, September 29.
VII.REFERENCES

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• Moinuddin Sarkar, Mohammad. “M , Agricultural waste plastics conversion
into high energy liquid hydrocarbon fuel by thermal degradation
process”, Journal of Petroleum Technology and Alternative Fuels,2011, Vol.
2(8), pp. 141145.
• J. Aguayo D.P.& Serrano, “European trends in the feedstock recycling of
plastic wastes”, global nest Journal, 2007, Vol. 9, No 1, pp 12-19.
• V. Belgiorno, G. De Feo, “Energy from gasification of solid wastes”, 2003,
pp 1–15.
• Guang-Hua Zhang ,Jun-Feng Zhu, “Prospect and current status of
recycling waste plastics and technology for converting them into oil in
China”, 2006,pp 231-239.
• Jenni, Ylä-Mella, “Recycling of polymers, Department of Process and
Environmental Engineering”, 2005,pp.1-9.
• S.M. Al-Salem ,P.Lettieri, “Recycling and recovery routes of plastic solid
waste (PSW)”, (2009),vol. 29,pp. 2625–2643.

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Thank you

GMR Mechanical Dept generates fuel from plastic waste

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