Plastic to Fuel Machine

Plastic To Fuel Machine ProjectReport2014
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A PROJECT REPORT ON
PLASTIC TO FUEL MACHINE
2014
Submitted in partial fulfilment of the requirements for the award of the degree of
Bachelor of Technology in
Polymer Engineering of Mahatma Gandhi University
BY
AJMAL ROSHAN T. J, SWATHI E& SANJAY R.
Department of Polymer Engineering
Mahatma Gandhi University College of Engineering
Muttom P. O, Thodupuzha, Kerala – 685 587

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MAHATMA GANDHI UNIVERSITY COLLEGE OF ENGINEERING
Muttom P.O, Thodupuzha, Kerala – 685 587
DEPARTMENT OF POLYMER ENGINEERING
CERTIFICATE
This is to certify that the report entitled “PLASTIC TO FUEL MACHINE”,
submitted by AJMAL ROSHAN T. J.(Reg.No.10018674), SWATHI E.(Reg.No.10018699)
& SANJAY R. (Reg.No.10018692) to the Department of Polymer Engineering, Mahatma
Gandhi University College of Engineering, Thodupuzha, in partial fulfilment of the
requirements for the award of the degree of Bachelor of Technology in Polymer Engineering
from Mahatma Gandhi University, Kottayam, Kerala, is an authentic report of the project
presented by them during the academic year 2013-2014.
Dr. Josephine George
Head of the Department
Polymer Engineering

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ACKNOWLEDGEMENT
The successful completion of any task is incomplete if we do not mention
the people who made it possible. It is a Great pleasure to express our sincere
gratitude to Prof. K.T. SUBRAMANIAN, Principal, MGUCE, for his
guidance, advice and encouragement.
We are greatly indebted to Dr. Josephine George, Head of the
Department of Polymer Engineering, for her valuable help and guidance at
different stages of this work.
We thank all the faculty and staff of Polymer Engineering department,
faculties of fuel testing lab at National Institute of Technology- Calicut, our
friends and family for their support and constant encouragement throughout this
work.
Above all we thank GOD almighty without whom this task would not
have been a success.
AJMAL ROSHAN T. J, SWATHI E& SANJAY R.

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About the Team
1. Dr. Josephine George
H.O.D.
Polymer Engineering,
Mahatma Gandhi University College of Engineering, Thodupuzha.
2. AJMAL ROSHAN T. J.
THAMARATH HOUSE
PALAYOOR CHURCH ROAD
CHACVAKKAD P.O.
THRISSUR-680506
E- mail: ajmalroshan27@gmail.com
Mob: 9961161870
3. SANJAY R.
MENASSERIL HOUSE
C.M.C-1,
CHERTHALA P.O.
ALAPUZHA-688524
E- mail: ucesanjay@gmail.com
Mob:- 9995069478
4. Swathi E.
E-mail: swthe5@gmail.com

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CONTENTS
1. Abstract…………………………………………………………………..7
2. Introduction
2.1. Plastics…………………………………….………...……………….8
2.2. Common Plastic Uses…….………………………………………….9
2.3. Special-Purpose Plastics……….…………………………………...10
2.4. Advantages of Plastic………………………..……………………...11
2.5. Disadvantages of Plastic……………………….……………………11
2.6. Plastic Production, Consumption and Growth……….……….......12
2.7. Plastics in Procurement………….…….…………………..………13
2.8. Manufacture………………………….…………...…………...…....13
2.9. Health Impacts of Manufacture…..……………...…...…….…......14
2.10. Sources and Types of Plastic Wastes…………….………….…...15
2.11. Plastic Waste Recycling………………………...…………….…..16
2.12. Some Attempts for Plastic Recycling……..……………………...18
2.13. Alternative Methods…………………..……………………….....20
3. Objective…………………………………..…………..………………...22
4. Experimental details
4.1. Principles of the Machine………………………………...…..…22

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4.2. Process Carried Out in the Machine
4.2.1. Pyrolysis………………………………………...…………23
4.2.2. Process…………………………………………………..…23
4.3. Parts of the Machine
4.3.1 Reactor………………...……………….…………….…….24
4.3.2. Catalytic cracker………………………..………….……..26
4.3.3. Condenser…………….…………………………….……..27
4.3.4. Nitrogen Cylinder….……………………………………..28
4.4.Materials used…….…………………...……………….…………28
4.5. Laboratory Set Up……………………………………………….30
4.6. Process to be carried out………………...……….……..……….31
4.7. Inferences Drawn From Experiment…..………….……….…...32
5. Test for Characterizing Output
5.1. Calorific Value……………..……………………………….……33
5.1.1 Principle………………………………….……..………….33
5.1.2. Procedure……………..…..………………...……………..34
5.1.3. Calculations……………………...………...…………...….35
5.2. Viscosity………………………………………………...…………36
5.3. Acidity (Acid value)
5.3.1. Definition…….…………………………....………..…..….37

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5.3.2. Procedure……….…...……………………...........….…….38
5.4. Density and Specific Gravity.……………………..…..….……..38
6. Results and Discussions
6.1. Test Results
6.1.1. Calorific Value………………………..………..…..……40
6.1.2. Viscosity…………….………………………….…………42
6.1.3. Acidity (Acid value)..........................................................44
6.1.4. Density and Specific Gravity……………..……..…..….46
6.2. Role of Catalyst in the process……..…....….…..…………….50
6.3. Molecular Structure of the Catalyst….……….…………….51
6.4 Process taking place in a Catalytic Reactor ……...………….51
6.5. Features of Catalyst to be used…………..……….…….…….52
6.6. Cracking of Molecules in Reactor in Presence of Catalyst....53
6.7. Regeneration of catalyst………………………...…………….53
6.8. Need of Catalytic Cracking………...……….………………...54
7. Conclusion…………………………………………………..………..….55
8. References…………………………………………………….…............56
9. Certifications,……………………………………………………………58

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1. ABSTRACT
Polymers are finding extensive application in our day to day life. The
low density, high strength to weight ratio, ease of processing etc. make them attractive over
other conventional materials. The various fields of applications of polymers includes different
sectors such as structural and non-structural, automobile, medical, aerospace etc. Extensive
use results in accumulation of waste plastics. The safe disposal of waste plastics is a major
problem faced by the polymer industry. The combustion of polymers can release so many
toxic gases to the atmosphere and can lead to major environmental hazards. Since crude oil is
the starting material for the production of plastic, the reverse processing of plastic back to
crude oil is an innovative method for better disposal of plastics. Waste plastics are heated in a
reactor at a temperature of about 350- 450℃provided with an inert atmosphere. The waste
plastics used include, Polyethylene (PE), Polypropylene (PP), and Polystyrene (PS). The long
chain molecules of these plastics is first broken into shorter chain molecules in the reactor
and then broken into small molecules in the catalytic cracker. The final product is mixed oil
that consists of gasoline, diesel oil, kerosene and the like. The machine and process for
making oil are totally based on environment-friendly concept. Plastics suitable for converting
into oil are PP (Garbage bag, cookie bag, CD case, etc.), PE (Vinyl bag, medical product, cap
of PET bottle etc.) and PS (Cup Noodle Bowl, lunch box, Styrofoam etc.).

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2. INTRODUCTION
2.1. Plastics
As a brief introduction to plastics, it can be said that 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. These polymers can be moulded or extruded into desired shapes. Plastic is the
general common term for a wide range of synthetic or semi-synthetic organic amorphous
solid materials used in the manufacture of industrial products. Plastics are typically polymers
of high molecular mass, and may contain other substances to improve performance and/or
reduce costs. Monomers of Plastic are either natural or synthetic organic compounds. The
word is derived from the Greek past (plastikos) meaning fit for moulding, and past (plastos)
meaning moulded. It refers to their malleability or plasticity during manufacture that allows
them to be cast, pressed, or extruded into a variety of shapes such as films, fibres, plates,
tubes, bottles, boxes, and much more. The common word plastic should not be confused with
the technical adjective plastic, which is applied to any material which undergoes a permanent
change of shape (plastic deformation) when strained beyond a certain point. Aluminium, for
instance, is plastic in this sense, but not a plastic in the common sense; in contrast, in their
finished forms, some plastics will break before deforming and therefore are not plastic in the
technical sense. There are two main types of plastics: thermoplastics and thermosetting
polymers.
 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.
 Thermosets or thermosettings can melt and take shape only once. They are not
suitable for repeated heat treatments; therefore after they have solidified, they stay
solid. Examples are phenol formaldehyde and urea formaldehyde

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2.2. Common Plastic Uses
 Polypropylene(PP) - Food containers, appliances, car fenders (bumpers), plastic
pressure pipe systems.
 Polystyrene(PS) - Packaging foam, food containers, disposable cups, plates, cutlery,
CD and cassette boxes.
 High impact polystyrene (HIPS) - Fridge liners, food packaging, vending cups.
 Acrylonitrile butadiene styrene (ABS)
Electronic equipment cases (e.g., computer monitors, printers, keyboards), drainage
pipe
 Polyethylene terephthalate (PET)
Carbonated drinks bottles, jars, plastic film, microwavable packaging.
 Polyester (PES)
Fibers,textiles.
 Polyamides (PA) (Nylons)
Fibers, toothbrush bristles, fishing line, under-the-hood car engine mouldings.
 Polyvinyl chloride (PVC)
Plumbing pipes and guttering, shower curtains, window frames, flooring.
 Polyurethanes (PU)
Cushioning foams, thermal insulation foams, surface coatings, printing rollers.
(Currently 6th or 7th most commonly used plastic material, for instance the most
commonly used plastic found in cars).
 Polyvinylidene chloride (PVDC) (Saran)
Food packaging.
 Polyethylene (PE)
Wide range of inexpensive uses including supermarket bags, plastic bottles.
 Polycarbonate/Acrylonitrile Butadiene Styrene (PC/ABS)
A blend of PC and ABS that creates a stronger plastic. Used in car interior and
exterior parts,and mobile phone bodies.

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2.3. Special-Purpose Plastics:
 Polymethyl methacrylate (PMMA)
Contact lenses, glazing (best known in this form by its various trade names around the
world; e.g., Perspex, Oroglas, Plexiglas), aglets, fluorescent light diffusers, rear light
covers for vehicles.
 Polytetrafluoroethylene (PTFE)
Heat-resistant, low-friction coatings, used in things like non-stick surfaces for frying
pans, plumber's tape and water slides. It is more commonly known as Teflon.
 Polyetheretherketone (PEEK) (Polyetherketone)
Strong, chemical- and heat-resistant thermoplastic, biocompatibility allows for use in
medical implant applications, aerospace mouldings. One of the most expensive
commercial polymers.
 Polyetherimide (PEI) (Ultem)
A high temperature, chemically stable polymer that does not crystallize.
 Phenolics (PF) or (phenol formaldehydes)
High modulus, relatively heat resistant, and excellent fire resistant polymer. Used for
insulating parts in electrical fixtures, paper laminated products (e.g., Formica),
thermally insulation foams. It is a thermosetting plastic, with the familiar trade name
Bakelite, that can be moulded by heat and pressure when mixed with a filler-like
wood flour or can be cast in its unfilled liquid form or cast as foam (e.g., Oasis).
Problems include the probability of mouldings naturally being dark colours (red,
green, brown), and as thermoset difficult to recycle.
 Urea-formaldehyde (UF)
One of the aminoplasts and used as a multi-colorable alternative to phenolics. Used as
a wood adhesive (for plywood, chipboard, hardboard) and electrical switch housings.
 Melamine formaldehyde (MF)
One of the aminoplasts, and used as a multi-colorable alternative to phenolics, for
instance in mouldings (e.g., break-resistance alternatives to ceramic cups, plates and
bowls for children) and the decorated top surface layer of the paper laminates (e.g.,
Formica).

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 Polylactic acid (PLA)
A biodegradable, thermoplastic found converted into a variety of aliphatic polyesters
derived from lactic acid which in turn can be made by fermentation of various
agricultural products such as corn starch, once made from dairy products
2.4. Advantages of Plastic:
1) They are light in weight.
2) They are strong, good and cheap to produce.
3) They are unbreakable
4) Used to make - Water bottles, pens, plastic bags, cups etc.
5) They are good water resistant and have good adhesive properties.
6) They can be easily moulded and have excellent finishing
7) They are corrosion resistant.
8) They are chemical resistant
9) Plastic is used for building, construction, electronics, packaging and transportation
industries.
10) They are odourless.
2.5. Disadvantages of Plastic:
1) They are non renewable resources.
2) They produce toxic fumes when burnt.
3) They are low heat resistant and poor ductility.
4) They are non biodegradable.
5) They harm the environment by choking the drains.
6) The poisonous gaseous product produced by the decomposition plastic can causes
CANCER
7) They are embrittlement at low temperature and deformation at high pressure.
8) The recycling of plastic is not cost effective process and even more expensive
compare to its manufacturing.

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9) Plastic materials like plastic bags are mostly end up as harmful waste in landfill which
may pollute the environment and threatening our health.
10) The biodegradation of plastic takes 500 to 1,000 years Japan
2.6. Plastic Production, Consumption and Growth
Economic growth and changing consumption and production patterns are
resulting into rapid increase in generation of waste plastics in the world. In Asia and the
Pacific, as well as many other developing regions, plastic consumption has increased much
more than the world average due to rapid urbanization and economic development. The
world‟s annual consumption of plastic materials has increased from around 5 million tonnes
in the 1950s to nearly 100 million tonnes; thus, 20 times more plastic is produced today than
50 years ago. This implies that on the one hand, more resources are being used to meet the
increased demand of plastic, and on the other hand, more plastic waste is being generated.
Due to the increase in generation, waste plastics are becoming a major stream in solid waste.
After food waste and paper waste, plastic waste is the major constitute of municipal and
industrial waste in cities. Even the cities with low economic growth have started producing
more plastic waste due to plastic packaging, plastic shopping bags, PET bottles and other
goods/appliances using plastic as the major component. This increase has turned into a major
challenge for local authorities, responsible for solid waste management and sanitation. Due to
lack of integrated solid waste management, most of the plastic waste is neither collected
properly nor disposed of in appropriate manner to avoid its negative impacts on environment
and public health and waste plastics are causing littering and chocking of sewerage system.
The World's annual consumption of plastic materials has increased from around 5 to nearly
100 million tonnes in the last 50 years, with plastic being the material of choice in nearly half
of all packaged goods. The poverty-related impacts arising from plastics are complex and lie
in the areas of health and disposal and they mainly occur in parts of the developing world. In
addition, plastic production use and disposal also has a range of environmental impacts which
has been the focus of much concern from NGOs, scientists and policy makers. There are also
crosscutting poverty, health and social issues related to plastics.

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2.7. Plastics in Procurement
Plastic is a miracle material that has supported and driven innovation in the
supply and delivery of products, but also a problematic substance that uses non-renewable
resources, creates pollution in manufacture and use and presents a global issue for disposal.
Plastics are found in a vast range of products, either as a primary material or as a component.
Plastics have also, due to reasons of weight, flexibility, usability and cost, become a primary
material used for packaging, containers, furniture and construction materials. As a result of
this diverse range of uses it is likely that many procurement activities will involve the
purchase of plastics either directly or indirectly.
2.8. Manufacture
The vast majority of plastics are produced from the processing of
petrochemicals (derived from crude oil). In the US, plastic manufacture (as a feedstock and
energy source) is estimated to consume approximately 4.6% of total oil consumption (US
Energy Information Association, 2009). Petrochemical based plastics are manufactured
through the “cracking” of oil and natural gas in order to produce different hydrocarbons.
These are chemically processed to produce monomers (small chemical molecules that can
bond with others) which then undergo a polymerisation process (bonding with other
monomers into long chain chemicals) to produce polymers. These undergo further
processing, normally using additives to change their “feel”, colour or performance, to
produce feedstock. Usually in the form of pellets, this can be transported and further
processed through heat and moulding to make finished products. As with any heavy industrial
process, plastics manufacture can give rise to a range of environmental and social impacts,
some of which can give rise to poverty considerations. Pollution of water courses and local
air quality impacts in parts of the developing world can directly affect the quality of life and
opportunities of local people, as they often depend upon fishing and hunting for their
livelihoods.

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2.9. Health Impacts of Manufacture
Historically many plastics have been considered to be generally inert. There has
been extensive study and discussion in recent years over pollution and health impacts arising
from plastics. Concern has focused upon plastic additives (such as plasticizers - used to
enhance the feel of plastics, and flame retardants) which can directly affect human health or
which are chemically similar to human hormones and therefore act to disrupt biochemical
processes. These chemicals are “bio-accumulative”, meaning that they build up in the body
over time and can cause or contribute to a range of health problems. PVC (Polyvinyl
Chloride) has given rise to the most concern, partly as its uses are so widespread, and partly
because it is treated with many plasticizers that enhance its feel which are thought to be bio-
accumulative. There is still much debate over the validity and extent of such concerns, in
general NGOs and some health organizations have raised concerns, whilst plastics
manufacturers have sought to demonstrate the safety of their products. As petrochemically
derived plastics do not degrade, the accumulation of waste, in areas of the developing world
has become a key environmental and social issue. While the environmental issues related to
this are perhaps clear, the social and poverty issues are more complex. Significant amounts of
plastic waste from the UK and other countries are shipped to the developing world. This
waste is either recycled to make new plastic feedstock or ends up in dumps or waste sites. In
addition, plastic waste can also find its way into the world's oceans where it can have a
significant impact upon marine habitats and wildlife, and an associated impact upon those
communities that depend upon fishing for their livelihoods. Once example is known as the
“Great Pacific Garbage Patch” which is estimated to be twice the size of Texas and contains
over 3 million tonnes of plastic waste. Plastic waste in the developing world is considered to
be both a contributor and possible solution to poverty issues. A number of studies have
focussed upon the economic opportunities afforded to the poor through recycling plastics
which are disposed of in their local environment. As with many poverty and environmental
issues, whether such disposal is considered to be ultimately positive or negative is perhaps a
moot point. However, plastic waste and its safe disposal is the responsibility of all
organizations using this commodity.

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Figure 1: Plastic waste are used for land filling.
2.10. Sources and Types of Plastic Wastes
Plastic wastes arise from different sources, commercial, industrial, household, construction,
demolition, radioactive and hospital wastes. Plastic in commercial wastes, such as from retail
stores and offices, are managed alone with other wastes from their sources and usually
combined with household wastes. Special source of plastic waste is discarded agriculture
mulch (film).
Table 1: Plastics and their products
Sl. No. Types of plastics Industries
1 High Density Polyethylene
(HDPE)
Plastic containers
2 Low Density Polyethylene (LDPE) Milk bags and other packaging
materials
3 Polypropylene (PP) Plastic ropes and cups

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Apart from these, we do use polymers as coating material in paint industries and adhesive
industries but these do not come as a plastic waste. The various source of plastics wastes are
given below:
Table 2: Waste generation from plastics
2.11. Plastic Waste Recycling
On the other hand, plastic waste recycling can provide an opportunity to
collect and dispose of plastic waste in the most environmental friendly way and it can be
converted into a resource. Thermoplastic wastes can be recycled. Recycling of thermosetting
materials is more difficult because of the properties of these materials, but they are recycled
as fuel and are used sometimes, by grinding, as fillers in the new thermosetting materials. For
example, large volumes of tyres from cars, bicycles and tricycles, find application as
materials for calorific utilization .In contrast to siting of new landfills or incinerators
facilities, recycling tends to be a politically popular alternatives for the most part. At
industrial scrap level, recycling of plastics grew rapidly after the increase in oil prices of the
mid 1970‟s and it now occupies a common place.
Plastic recycling requires information in following three areas:
 Collection and Separation of plastic wastes
 Reprocessing technology
 Economic viability of the recycled products
In terms of world technology, Europe is the most advanced in recycling and
separation of different plastics. Despite practicing recycling within a manufacturing system,
Sl. No. Types of Wastes Mode of Generation
1 Post-Consumer Plastics By the consumers
2 Industrial Plastics Various industrial Sectors
3 Scrap Plastics and fabricator By the plastic compounder
4 Nuisance Plastics Plastic wastes that find
difficult in recycling

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Japan seems to be devoted to incineration and the use of ash in end products. In the North
America the current incentive for research in these areas is driven by the rapid reduction of
environmentally safe landfill and expensive systems required for incineration.
The recycling concept of plastics, in effect made its beginning in India in late
sixties. Though earlier on cottage scale, scrap cellulose acetate film and acrylic scrap
continued to find their place in the bangle industry as also for recovery of monomer. For a
long time, no attempt seem to have been made to record and quantify the plastic wastes,
collected from various sources and get converted into a range of plastics finished goods; Nor
have there been any attempts to regulate or standardize the quality of recycled materials used.
The recycling metals, papers and glasses are quite advanced in India, but the recycling of
plastics is not viable due to the following reasons:
 Less quantity of plastic wastes
 Limited technology available for recycling of plastic.
In addition, in other countries, the composition and constituent of the plastic is
explicitly written on the products while in India manufacturers hide these information due to
trade secret. This poses problems in the recycling of plastics. The management of plastics
waste could be a major problem, and whether this would be environmentally friendly, is
required to be assessed carefully. With the size of our country and the requirement of plastics
as useful materials for various domestic and industrial applications, it would not be
appropriate to classify “plastics” as environmental hazards, as these certainly do not become
a “hazard” even if these go into garbage as wastes or in fact discarded items. Their collection,
sorting and recycling and reuse and judiciously for identified critical and non-critical
applications with a view to recover the raw materials, are important issues that need to be
regulated and coordinated.
2.12. Some Attempts for Plastic Recycling
In most of the situations, plastic waste recycling could also be economically
viable, as it generates resources, which are in high demand. Plastic waste recycling also has a
great potential for resource conservation and GHG emissions reduction, such as producing
diesel fuel from plastic waste. This resource conservation goal is very important for most of
the national and local governments, where rapid industrialization and economic development
is putting a lot of pressure on natural resources. Some of the developed countries have

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already established commercial level resource recovery from waste plastics. Therefore,
having a “latecomer‟s advantage,” developing countries can learn from these experiences and
technologies available to them.
To raise the awareness and to build the capacity of local stakeholders, UNEP has
started to promote Integrated Solid Waste Management (ISWM) system based on 3R
(reduce, reuse and recycle) principle. This covers all the waste streams and all the stages of
waste management chain, viz.: source segregation, collection and transportation, treatment
and material/energy recovery and final disposal. It has been shown that with appropriate
segregation and recycling system significant quantity of waste can be diverted from landfills
and converted into resource. Developing and implementing ISWM requires comprehensive
data on present and anticipated waste situations, supportive policy frameworks, knowledge
and capacity to develop plans/systems, proper use of environmentally sound technologies,
and appropriate financial instruments to support its implementation. Many national
governments, therefore, have approached UNEP, [as reflected in the decision taken by the
UNEP Governing Council/Global Ministerial Environment Forum during its 25th
Session in
February 2009 (UNEP/GC.25/CW/L.3)] to get further support for their national and local
efforts in implementation of the Integrated Solid Waste Management (ISWM) programme.
Plastics are durable and degrade very slowly; the molecular
bonds that make plastic so durable make it equally resistant to natural processes of
degradation. Since the 1950s, one billion tons of plastic has been discarded and may persist
for hundreds or even thousands of years. In some cases, burning plastic can release toxic
fumes. Burning the plastic polyvinyl chloride (PVC) may create dioxin. Also, the
manufacturing of plastics often creates large quantities of chemical pollutants. By 1995,
plastic recycling programs were common in the United States and elsewhere. Thermoplastics
can be remelted and reused, and thermoset plastics can be ground up and used as filler,
though the purity of the material tends to degrade with each reuse cycle. There are methods
by which plastics can be broken back down to a feedstock state.
To assist recycling of disposable items, the Plastic Bottle Institute of the Society of the
Plastics Industry devised a now-familiar scheme to mark plastic bottles by plastic type. A
plastic container using this scheme is marked with a triangle of three cyclic arrows, which
encloses a number giving the plastic type:

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Table 3: Plastic identification code
2.13. Alternative Methods
Unfortunately, recycling plastics has proven difficult. The biggest problem
with plastic recycling is that it is difficult to automate the sorting of plastic waste, and so it is
labour intensive. Typically, workers sort the plastic by looking at the resin identification
code, though common containers like soda bottles can be sorted from memory. Other
recyclable materials, such as metals, are easier to process mechanically. However, new
mechanical sorting processes are being utilized to increase plastic recycling capacity and
efficiency.
While containers are usually made from a single type and colour of plastic, making them
relatively easy to sort out, a consumer product like a cellular phone may have many small
parts consisting of over a dozen different types and colours of plastics. In a case like this, the
resources it would take to separate the plastics far exceed their value and the item is
discarded. However, developments are taking place in the field of Active Disassembly, which
may result in more consumer product components being re-used or recycled. Recycling

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certain types of plastics can be unprofitable, as well. For example, polystyrene is rarely
recycled because it is usually not cost effective. These un-recycled wastes are typically
disposed of in landfills, incinerated or used to produce electricity at waste-to-energy plants.
The biggest threat to the conventional plastics industry is most likely to be
environmental concerns, including the release of toxic pollutants, greenhouse gas, non-
biodegradable landfill impact as a result of the production and disposal of plastics. Of
particular concern has been the recent accumulation of enormous quantities of plastic trash in
ocean gyres.
Hence we should find a suitable solution for the existence of these waste plastics in
our environment. The plastic to fuel machine deals with the recycling of plastics into suitable
form of fuel. For many years, various methods are tried and tested for processing of waste
plastic. The plastic materials are recycled and low value products are prepared. Plastic
materials which cannot be recycled are usually dumped into undesirable landfill. Worldwide
almost 20% of the waste stream is plastic, most of which still ends up in landfill or at worst it
is incinerated. This is a terrible waste of a valuable resource containing a high level of latent
energy. In recent year this practice has become less and less desirable due to opposition from
Government and environmentally conscious community groups. The value of plastics going
to landfill is showing a marginal reduction despite extensive community awareness and
education programs. Research Centre for Fuel Generation (RCFG) has conducted successful
300 successful pilot trials and commercial trials for conversion of waste plastic materials into
high grade industrial fuel. The system uses liquefaction, pyrolysis and the catalytic
breakdown of plastic materials and conversion into industrial fuel and gases. The system can
handle the majority of plastic materials that are currently being sent to landfill or which have
a low recycle value. Catalytic conversion of waste plastic into high value product is a
superior method of reusing this valuable resource.
The distillate fuel is an excellent fuel and can be used for
1) Diesel electrical generators
2) Diesel burners / stoves
3) Boilers
4) Hot air generators

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5) Hot water generators
6) Diesel pumps
The distillate can be further fractionated into fuels as under and can be used in automobiles.
1) Petrol
2) Kerosene
3) Diesel
3. OBJECTIVE
Use of plastics are increasing day by day. One of the major problem following it is
the disposal of the waste generated from plastics. Since plastics are made from crude oil why
can‟t it be reverse processed. i.e., plastics back to crude oil. This is the basic idea behind our
project. Besides helping to remove a lot of the 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. Petroleum
based fuels are becoming exhausted by the increased consumption of fuel by the ever
expanding automobile sector. It is very important to find an alternative to meet the increased
demand of fuels. In the present project, a method is suggested to convert waste plastics to
useful fuel. The objective of the work is to develop a machine which converts plastics to
some useful form of fuel. A new and innovative technology for this process is by catalytic
conversion method. It is an efficient way for recycling of plastics. Cleaned and dried plastic
waste is melted at high temperature in an inert nitrogen atmosphere. Vaporization takes place
and the vapours are passed through catalytic cracker and then condensed. Purpose of the
catalytic cracker is to act as a molecular sieve which will permit only the passage of small
hydrocarbon chains less than C₈ (octanes). The condensates thus obtained have composition
of gasoline, diesel and kerosene. Hence this can be used as a source of energy.

23
4. Experimental Details
4.1. Principles of the Machine
All plastics are polymers mostly containing carbon and hydrogen and few other
elements like chlorine, nitrogen, etc. Polymers are made up of small molecules, called
monomers, which combine together and form large molecules, called polymers.
When this long chain of polymers breaks at certain points, or when lower molecular weight
fractions are formed, this is termed as degradation of polymers. This is reverse of
polymerization or de-polymerization.
If such breaking of long polymeric chain or scission of bonds occurs randomly, it is
called Random depolymerization. Here the polymer degrades to lower molecular fragments.
In the process of conversion of waste plastics into fuels, random depolymerization is carried
out in a specially designed reactor in the absence of oxygen and in the presence of coal and
certain catalytic additives. The maximum reaction temperature is 350°C. There is total
conversion of waste plastics into value-added fuel products.
4.2. ProcessCarried out in the Machine
4.2.1. Pyrolysis
Pyrolysis is a process of thermal degradation in the absence of oxygen. Plastic
& Rubber waste is continuously treated in a cylindrical chamber and the pyrolytic gases are
condensed in a specially-designed condenser system. This yields a hydrocarbon distillate
comprising straight and branched chain aliphatic, cyclic aliphatic and aromatic hydrocarbons.
The resulting mixture is essentially the equivalent to petroleum distillate. The plastic / Rubber
is pyrolised at 350-450⁰C and the pyrolysis gases are condensed in a series of condensers to
give a low sulphur content distillate. Pyrolysis is a very promising and reliable technology for
the chemical recycling of plastic wastes. Countries like UK, USA, and Germany etc have

24
successfully implemented this technology and commercial production of monomers using
pyrolysis has already begun there.
Pyrolysis offers a great hope in generating fuel oils, which are heavily priced
now. This reduces the economical burden on developing countries. The capital cost required
to invest on pyrolysis plant is low compared to other technologies. So, this technology may
be an initiative to solve fuel crisis and the problems due to disposal of plastics.
4.2.2. Process
Under controlled reaction conditions, plastics materials undergo random de-
polymerization and are converted into three products:
a) Solid Fuel i.e., Coke
b) Liquid Fuel i.e., Combination of Gasoline, Kerosene, Diesel and Lube Oil
c) Gaseous Fuel i.e., LPG range gas
The process consists of two steps:
i) Random de-polymerization
- Loading of waste plastics into the reactor along with the Catalyst system.
- Random de-polymerization of the waste plastics.
ii) Fractional Distillation
- Separation of various liquid fuels by virtue of the difference in their boiling points.
One important factor of the quality of the liquid fuel is that the sulphur content is less than
0.002ppm which is much lower than the level found in regular fuel.
4.3. Parts of the Machine
4.3.1 REACTOR
Reactor is the major component of this machine. There are certain critical factors and
they are
 Type of feed
 Reactor atmosphere

25
 Temperature
 Pressure
Typical Feedfor the Machine
Table 4: Typical Feed for Machine
Sl.
No.
POLYMER DESCRIPTION As a feed stock
for liquid fuel
1 PE, PP, PS Typical feed stock for
fuel production due to
high heat value and
clean exhaust gas
Allowed

26
2 PET, Phenolic resin ,PVA,
polyoxymethylene
Lower heat value than
above plastics
Not allowed
3 Polyamide,
Polyurethane,Polysulphide
Fuel from this type of
plastics is a hazardous
component such as NOx
and Sox in flue gas.
Not allowed
4 PVC, Poly vinylidene
chloride and fluro carbon
polymers.
Source of hazardous and
corrosive flue gas up on
thermal treatment and
combustion
Not allowed
From the table it is very clear that the typical feed in the machine are PE,PP and PS
4.3.2. CATALYTIC CRACKER
Catalytic cracking is the breaking of large hydrocarbon molecules into smaller and
more useful bits. Catalytic cracker is provided with catalyst inside. The cracker must be
designed in such a way that the vapour from the reactor must have maximum surface contact
with the catalyst. The catalyst will act as a molecular sieve which permits the passage of
small molecules. There is no single unique reaction happening in the cracker. The
hydrocarbon molecules are broken up in a fairly random way to produce mixtures of smaller
hydrocarbons, some of which have carbon-carbon double bonds.

27
4.3.3. CONDENSER
 It‟s the part of machine which condenses the vapours coming out from the catalytic
cracker.
 The condenser must condense the very hot vapors in an efficient manner to give the
condensate
 Clogging in the condenser must be prevented. This can be achieved by increasing the
diameter of the pipe
In this machine, we are using a spiral condenser to increase the efficiency of
condensation

28
4.3.4. NITROGEN CYLINDER
Inert atmosphere in the reactor is provided by pumping nitrogen from a nitrogen
cylinder attached to the reactor.
Purpose: plastic feed should not burn instead it should melt at high temperature inside the reactor.
4.4. Materials Used
Polymers used
Polyethylene (PE)
Polypropylene (PP)
Polystyrene (PS)

29
Catalyst Used
ZSM-5, Zeolite Socony Mobil–5, is an aluminosilicatezeolite belonging to the
pentasil family of zeolites. Its chemical formula is NanAlnSi96–nO192·16H2O (0<n<27).
Patented by Mobil Oil Company in 1975, it is widely used in the petroleum industry as a
heterogeneous catalyst for hydrocarbonisomerization reactions.
Structure
ZSM-5 is composed of several pentasil units linked together by oxygen bridges to
form pentasil chains. A pentasil unit consists of eight five-membered rings. In these rings, the
vertices are Al or Si and an O is assumed to be bonded between the vertices. The pentasil
chains are interconnected by oxygen bridges to form corrugated sheets with 10-ring holes.
Like the pentasil units, each 10-ring hole has Al or Si as vertices with an O assumed to be
bonded between each vertex. Each corrugated sheet is connected by oxygen bridges to form a
structure with “straight 10-ring channels running parallel to the corrugations and sinusoidal
10-ring channels perpendicular to the sheets.” Adjacent layers of the sheets are related by an
inversion point. The estimated pore size of the channel running parallel with the corrugations
is 5.4–5.6 Å. The crystallographic unit cell of ZSM-5 has 96 T sites (Si or Al), 192 O sites,
and a number of compensating cations depending on the Si/Al ratio, which ranges from 12 to

30
infinity. The structure is orthorhombic (space group Pnma) at high temperatures, but a phase
transition to
the monoclinic space group P21/n.1.13 occurs on cooling below a transition temperature,
located between 300 and 350 K.
ZSM-5 catalyst was first synthesized by Argauer and Landolt in 1972. It is a medium
pore zeolite with channels defined by ten-membered rings. The synthesis involves three
different solutions. The first solution is the source of alumina, sodium ions, and hydroxide
ions; in the presence of excess base the alumina will form soluble Al(OH)4
–
ions. The second
solution has the tetrapropylammoniumcation that acts as a templating agent. The third
solution is the source of silica, one of the basic building blocks for the framework structure of
a zeolite. Mixing the three solutions produces supersaturated tetrapropylammonium ZSM-5,
which can be heated to recrystallize and produce a solid.
4.5.Laboratory Set Up
30g of weighed plastic granules are fed into the round bottom flask. The round bottom flask
is provided with a continuous supply of inert nitrogen gas using a nitrogen gas cylinder. Heat
is provided by using Bunsen burner which may be between 350-450⁰C. It is the temperature
at which plastic begins to melt and vaporise. The vapours are passed through the catalyst
which is kept at a certain temperature. The vapours are then condensed using a condenser
attached to round bottom flask. At the end of condenser, the distillate is collected. The
amount of distillate obtained is measured. The colour of the distillate is noted. The time and
temperature at which the distillate is obtained is also noted. 1ml of distillate is taken in a
china dish and it is ignited. It burns and the time taken for ignition is noted. The experiment is
repeated with different plastics such as LDPE, HDPE, PP, PS, plastic wastes (mainly plastic
carry bags, CD case etc.)

31
4.6. Process to be carried out:
 Pretreatment of plastics. i.e. removal of water and impurities
 Loading of treated plastic into fluidized bed reactor provided with refractory bricks.
 Heating the materials to 350-450 degree Celsius in an inert atmosphere.
 Inert atmosphere is provided by a nitrogen cylinder connected to the reactor.
 Carrying the vapours to a catalytic chamber provided with suitable catalyst
Purpose of catalyst is to crack long chain hydrocarbons into small chain
molecules. it is also involved the isomerisation of the molecules.ie, linear
hydrocarbon chain changed into branched because the branched ones have higher
octane number which is the major component of the fuel.

32
 Designing of the catalytic cracker in such a way that it should provide maximum
surface contact of the vapours with the catalyst.
Plastics that has been cut into coarse granules is fed into a trough. It then moves through
various tubes and chambers. Through the process, the plastic is heated into a liquid and then
into a gas, and then cooled. At the end, a light coloured oil drips from a spigot into a
receptable (The machine can process about 10kg of plastic and produce about 10 litres of oil
every hour and can run continuously around the clock). The only other by-products include a
tiny bit of carbon residue, CO2 and water vapour.
Just about any plastic can be fed into the machine. Paper labels and a little dirt won‟t
hurt it, but the material should be relatively dry. The oil that comes out is a blend of gasoline,
diesel, kerosene and some heavy oils. It can be fed directly into an oil furnace or could be
processed further into something that could go straight into a diesel car.
4.7.Inferences Drawn From Experiment
 Polystyrene (PS) is a solvent for rubber ( It dissolved the rubber tube used for the
experiment)
 Mainly polyethylene (PE), polypropylene (PP), polystyrene (PS) only gives such
distillate
 Plastic waste gives only less amount of distillate than pure polymer granules (since it
contains other additives in it)
 In case of polystyrene (PS), more smoky fumes are produced due to its structural
properties arising due to its aromatic structure
 Because the entire process takes place inside vacuum and the plastic is melted and not
burned, minimal to no toxins are released in to the air
 Burning pure hydrocarbons such as PE and PP will produce a fuel that burns fairly
clean
 While burning PVC large amounts of chlorine will corrode the reactor and pollute the
environment

33
Different tests have been carried out to study and compare the fuel characteristics of different
samples and those of petrol and diesel which are used as the standard reference. The
characteristics which are studied are:
5. Test for Characterizing Output
5.1. Calorific Value
It is the amount of heat produced by the complete combustion of fuel. It is measured in
units of energy per amount of material.eg: kJ /kg
Instrument used : Bomb Calorimeter
5.1.1 Principle:

34
A weighed sample of the fuel is burned in oxygen in a bomb calorimeter under
controlled conditions. The calorific value is calculated from the weight of the sample and the
rise in temperature of the water.
1. Stand with illuminators and magnifiers
2. Thermometer
3. Motor
4. Stirrer
5. Lid
6. Outer jacket
7. Calorimeter vessel
8. Bomb assembly
9. Electrical connecting leads
10. Schrader valve
11. Ignition wire
12. Crucible
13. Water
14. Firing unit
5.1.2. Procedure
Weigh a suitable quantity of sample of fuel whose calorific value is to be found out,
in a stainless steel oil cup to the nearest 0.1 mg. For solid fuels make a pellet of the fuel and
weigh it to the nearest 0.1 mg. Place the pellet in the crucible inside the bomb.
Place the oil cup in the circular ring attached to the terminals of the bomb for liquid fuels.
Attach a length of nichrome wire across the bomb terminals. Weigh a suitable length of dry
cotton or a strip of filter paper, and tie or support it as the case requires, at the centre of
nichrome wire, so that its free end dips into the contents of the oil cup
Admit oxygen from the cylinder slowly, so that the oil is not blown from the cup until the
appropriate pressure is reached. For aviation and motor fuels, this pressure must lie between
25 and 30atm and for kerosene and heavier fuels between 25 and 27 atm.

35
The calorimeter vessel is filled with water such that the cover of the bomb will be submerged
within it when placed in position.
Place the prepared bomb with electrical leads, in the water in the calorimeter. Check that
there is no leakage of oxygen. Confirm that the firing leads are dead, and make the
appropriate connections. Put the cover in position, arrange the thermometer and stirrer in
position so that they do not touch the bomb or the vessel, and start the stirrer (driven by a
small induction motor).
The temperature of water is noted. Fire the charge by closing the firing circuit for two
seconds. Find out the maximum temperature attained by the water in the calorimeter.
Make sure that all the oil has burned.
5.1.3. Calculations
Mass of the sample burned = m grams
Initial water temperature = Ti
o
C
Final water temperature = Tf
0
C
Water equivalent of calorimeter, mw = 2350 gms
Specific heat of water , Cw = 4.187 J/gm/k
Let CV be the calorific value of the fuel burned. Then the heat of burning of fuel=
heat given to the calorimeter and water.
i.e. mCV = mwCw[Tf-Ti]
CV = mwCw[Tf-Ti]/m
Heat due to the burning of cotton strip is not taken into account.

36
5.2. Viscosity
 It is defined as measure of the resistance to gradual deformation by shear or tensile
stress.
For liquids, it refers to „thickness‟.
Unit is centipoise (cp)
 Instrument used : Cone and Plate Viscometer
Viscosity is the measure of the internal friction of a fluid. This friction becomes apparent
when a layer of fluid is made to move in relation to another layer. The greater the friction, the
greater the amount of force required to cause this movement, which is called shear. Shearing
occurs whenever the fluid is physically moved or distributed as in pouring, spreading,
spraying, mixing etc. Highly viscous fluids therefore require more force to move than less
viscous materials. Sir Isaac Newton postulated that, for straight, parallel, and uniform flow,
the shear stress τ between layers is proportional to the velocity gradient, du/dy, in the
direction perpendicular to the layers.
τ = η du
dy

37
Here the constant η is known as the coefficient of viscosity, the viscosity, the dynamic
viscosity or the Newtonian viscosity. The velocity gradient du/dy is a measure of the change
in speed at which the intermediate layers move with respect to each other and it describes the
shearing of the liquids, often referred as shear rate with unit as sec inverse the force per unit
area required top produce the shearing, is the shear stress (τ) and is expressed as dynes/cm2.
Thus, viscosity can be defined mathematically as
Poise= τ
du
dy
The absolute viscosity of samples under conditions of defined shear rate and shear
stress were determined by a programmable Brookfield DV-II + cone and plate viscometer
thermo stated in the temperature range 25-60+-1C. Its cone and plate spindle geometry
requires a sample volume of only 0.5 to 2ml and generates shear rates in the range of 0.6 to
1500 reciprocal seconds.
The Brookfield DV-II+ cone and plate viscometer is of the rotational variety. It
requires the torque that is needed to rotate an immersed element (the spindle) in a fluid. The
spindle is driven by a synchronous motor through a calibrated spring; the deflection of the
spring is indicated by a digital display. By using a multiple speed transmission and
interchangeable spindles a variety of viscosity ranges can be measured. For a given viscosity,
the viscous drag or resistance to flow is proportional to the spindle‟s speed of rotation and is
related to the spindle‟s size and shape (geometry).the drag will increase as the spindle size
and /or rotational speed increases. It follows that for a given spindle geometry and speed, an
increase in viscosity will be indicated by an increase in the deflection of the spring.
5.3. Acidity (Acid value)
5.3.1. Definition:
It is the mass of potassium hydroxide in milligrams that is required to neutralize 1g of
chemical substance

38
5.3.2. Procedure:
Known amount of sample dissolved in organic solvent is titrated with a solution of
KOH with known concentration and with phenolphthalein as a color indicator
2×0.56 g of KOH is dissolved in 200 ml of distilled water. Take this in a burette (50 ml). 1 g
of oil is added to 50 ml of methanol. Heat it at 400
C (put a magnetic stirrer). Add two drops
of phenolphthalein as colour indicator. Titrate against 0.1 M KOH. The end point value is
noted.
Acidity = 2 X 0.56/V
5.4. Density and Specific Gravity
Density is defined as mass per unit volume. Its unit is g/cm³
Specific gravity is defined as the ratio of density of a substance to the
density of a reference standard. Here, water is used as reference standard.
Instrument used : Density bottle
It is made of glass, consists of a closely fitting stopper and a capillary tube inside it.

39
A pycnometer also called specific gravity bottle, is a device used to determine
the density of a liquid. A pycnometer is usually made of glass, with a close-fitting ground
glass stopper with a capillary tube through it, so that air bubbles may escape from the
apparatus. This device enables a liquid's density to be measured accurately by reference to an
appropriate working fluid, such as water or mercury, using an analytical balance.
If the flask is weighed empty, full of water, and full of a liquid whose relative density is
desired, the relative density of the liquid can easily be calculated. The particle density of a
powder, to which the usual method of weighing cannot be applied, can also be determined
with a pycnometer. The powder is added to the pycnometer, which is then weighed, giving
the weight of the powder sample. The pycnometer is then filled with a liquid of known
density, in which the powder is completely insoluble. The weight of the displaced liquid can
then be determined, and hence the relative density or specific gravity of the powder.

40
6. RESULTS AND DISCUSSIONS
6.1. Test Results
6.1.1. Calorific value
SAMPLE CALORIFIC VALUE (kJ/kg)
PE 42829.65
PP 42145.91
PS 37881.08
PE
(catalyst)
43817.97
PP
(catalyst)
33866.58
PS
(catalyst)
38519.28
PE
WASTE
40252.30
PP
WASTE
37166.63
PS
WASTE
37344.74
Petrol 44400
diesel 43200

41
Calorific value vs. Polymer sample
X-axis: polymer sample Y-axis: calorific value
From the table and the graph, it can be concluded that calorific value of the
sample fuel is comparable to that of the reference petrol and diesel. Also, the calorific value
is increased on using the catalyst and the calorific value of the plastic waste is less than the
pure sample since it contains many other additives.
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst

42
6.1.2. Viscosity
SAMPLE VISCOSITY (cp)
PE 1.92
PP 1.15
PS 1.31
PE
(catalyst)
1.39
PP
(catalyst)
.82
PS
(catalyst)
0.89
PE
WASTE
.64
PP
WASTE
.41
PS
WASTE
.44
Petrol .33
diesel 3.22

43
Viscosity vs. Polymer sample
X-axis: polymer sample Y-axis: Viscosity
From the table and graph, it can be concluded that the viscosity is reduced on using
the catalyst and it is comparable to that of petrol and diesel. The relevance of the catalyst is
also very much understood from this test. The catalyst acts as a molecular sieve hence only
small hydrocarbon molecules are present in the output therefore their viscosity will be less
compared to samples without catalyst.
0
0.5
1
1.5
2
2.5
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst

44
6.1.3. Acidity
ACIDITY (in pH)
PE 2.26
PP 2.51
PS 2.06
PE
(catalyst)
1.13
PP
(catalyst)
1.243
PS
(catalyst)
2.26
PE
WASTE
1.384
PP
WASTE
1.299
PS
WASTE
1.424
Petrol 1.02
diesel 1.01

45
Acidity vs. Polymer sample
X-axis: polymer sample Y-axis: acidity
From the table and graph, it can be concluded that acidity of the samples is
closely approaching to the values of petrol and diesel and the values are reduced on using the
catalyst.
0
0.5
1
1.5
2
2.5
3
PE PP PS
pure sample
pure sample
with catalyst
plastic waste
with catalyst

46
6.1.4. Density and Specific Gravity
Density
(g/cm³)
Specific
gravity
PE 1.151 1.151
PP 1.143 1.143
PS 1.359 1.359
PE
(catalyst)
1.023 1.023
PP
(catalyst)
1.118 1.118
PS
(catalyst)
1.179 1.179
PE
WASTE
1.112 1.112
PP
WASTE
1.111 1.111
PS
WASTE
1.321 1.321
Petrol 1.063
Diesel 1.211

47
Density vs. Polymer sample
X-axis: polymer sample Y-axis: density
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst

48
Specific gravity vs. Polymer sample
X-axis: Polmer Sample Y-axis: specific gravity
From the table and graph, it can be concluded that both density and specific gravity of
the samples are closely approaching the values of the standard reference petrol and diesel.
Also, the values are increased on using the catalyst.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
PE PP PS
pure sample
pure sample with
catalyst
plastic waste with
catalyst

49
6.2. Role of Catalyst in the Process
Here the catalyst used is HZSM-5. The optimization of waste plastic as a function
of temperature in a batch mode reactor gave liquid yields of about 80% at a furnace
temperatures of about 600 degrees centigrade and one hr residence time. Sodium carbonate or
lime addition to the pyrolysis and co-processing reactors results into an effective chlorine
capture and the chlorine content of pyrolysis oil reduces to about 50-200ppm. The volatile
product from this process is scrubbed and condensed yielding about 10-15%gas and 75-80%
of a relatively heavy oil product.
The catalyst is a molecular sieve which will permit only the passage of small
hydrocarbon molecules through them. The relevance of catalyst is that, the desirable final
product is mixed oil that consists of gasoline, diesel oil and kerosene. In the absence of
molecular sieve (catalyst), the final product consists of large hydrocarbon chains which get
polymerized when brought into normal conditions. The presence of small chain hydrocarbons
in the product is achieved by the use of catalyst.
% Conversion Vs Catalyst
Figure: Comparison of HZSM--5 catalyst with other catalysts based on its performance
From figure , it is very clear that the performance of the catalyst HZSM-5 is very high compared to all
other catalysts. This is the reason why we use this particular catalyst in our machine.

50
6.3. Molecular Structure of the Catalyst
Figure: Molecular Structure of the Catalyst
From the figure, it is very clear that the catalyst is a molecular sieve which permits only the
passage of small hydrocarbon molecules through them.
ZSM-5, Zeolite Socony Mobil–5, is an aluminosilicatezeolite belonging to
the pentasil family of zeolites. Its chemical formula is NanAlnSi96–nO192·16H2O (0<n<27).
Patented by Mobil Oil Company in 1975, it is widely used in the petroleum industry as a
heterogeneous catalyst for hydrocarbon isomerization reactions.

51
6.4. Process taking place in a Catalytic Reactor:
Pictorial Representation:
6.5. Features of Catalyst to be used:
 Catalyst which is more selective to octanes
The octane is one of the molecule found in petrol. Hydrocarbons used in petrol
(gasoline) are given an octane rating which relates to how effectively they perform in

52
the engine. A hydrocarbon with a high octane rating burns more smoothly than one
with a low octane rating
 Catalyst which possess limited deactivation by coke
Coke is deposited on catalyst when vapors passes through them which may cause
catalyst deactivation
 Catalyst which possess high thermal stability
Vapors at high temperature is passing through the catalyst which will affect its
stability
6.6. Cracking of Molecules in Reactor in Presence of Catalyst
Table: Cracking of Molecules in Reactor in Presence of Catalyst

53
The figure shows the breaking of different hydrocarbon chains in the reactor in the presence
of the catalyst.
6.7. Regeneration of catalyst:
Coke will be deposited on catalyst during the process. But this catalyst can be regenerated by
burning. Hence, coke deposited is removed.
6.8. Need of Catalytic Cracking:
The final product we get is mixed oil that consists of gasoline, diesel
oil, kerosene. In absence of the molecular sieve(catalyst) , the final product consist of large
hydrocarbon chains which get polymerized when brought into normal conditions hence we
need to break or permit only the presence of small chain hydrocarbons in the product. This is
achieved by the catalytic cracker.

54
7. Conclusion
Cost for the fuel is increasing day by day and also the problem arising
due to the improper waste disposal of plastics are increasing in our country.
This plastic to fuel machine can solve both these problem in the most efficient
manner. This process offer many advantages such as:
1) Problem of disposal of waste plastic is solved.
2) Waste plastic is converted into high value fuels.
3) Environmental pollution is controlled.
4) Industrial and automobile fuel requirement shall be fulfilled to some extent at lower
price.
5) No pollutants are created during cracking of plastics.
6) The crude oil and the gas can be used for generation of electricity.
We have carried out the process with and without catalyst and the test results have improved
by using the catalyst:
 Calorific value increased
 Acid value decreased
 Viscosity decreased
 Density and specific gravity decreased
Lastly, further studies are required in future for economic improvementand its
design flexibility.

55
8. References
 Converting Waste Plastics into a Resource,
Compendium of Technologies
Compiled by
United Nations Environmental Programme
Division of Technology, Industry and Economics
International Environmental Technology Centre
Osaka/Shiga, Japan
 Thermal Decomposition of Polymers
Craig L. Beyler and Marcelo Hirschler
 Handbook of Fluidization and Fluid – Particle Systems
Edited by
Wen- Ching Yang (Siemens Westinghouse Power Corporation
Pittsburgh, Pennsylvania, U.S.A. MARCEL.
 Sustainable Plastics - website promoting bio plastics:
www.sustainableplastics.org/
 US Energy Information Association: Crude Oil facts
FAQs:www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plastics
 ChemTrust – information on Chemicals and Health: www.chemtrust.org.uk/
 Plastics Industry Perspective on the health impacts from PVC:
www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditives
 Polymer degradation to fuels over micro-porous catalysts as a novel tertiary
plastic recycling method, Polymer Degradation and
Stability

56
KarishmaGobin, George Manos
 Thermal degradation of municipal plastic waste for production of fuel-like
hydrocarbons, Polymer Degradation and Stability
N. Miskolczia, L. Barthaa, G. Dea´ka, B. Jo´ verb

57
Certifications

58

59

60

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