FUEL EXTRACTION FROM PLASTIC In this project we have designed , Fabricated and modelled (in CATIA) a Mini Pyrolysis device in which waste plastic is directly converted into fuel oil by a process called PYROLYSIS. Properties of oil like Flash point, Firepoint, Smoke point, Boiling point etc are tested and found they are similar to the properties of Diesel.

1. UNDER THE GUIDANCE OF
Mr. ABDULARIF M.TECH
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
FUEL EXTRACTION FROM PLASTIC

2. PROJECT BY
V.V.MANIKANTHA (15P31A03B8) K.V.V.V.RAM GANESH (15P31A0384)
D.V.MALLIKARJUNA (16P35A0317) K.N.V.D. AJAY (16P35A0321)
K.S.SWAROOP (15P31A0380) K.S.K.L.REDDY (15P31A0386)
M.HAREESH KUMAR (15P31A0388) R.DURGA KUMAR (15P31A03A3)
P. VARUN SANDEEP (15P31A0397) A.VINOD KUMAR (16P35A0314)

3. ABSTRACT
Extensive use of plastics in various industries results in
accumulation of waste. Safe disposal has become difficult and
combustion may release toxic gases into the atmosphere.
There is a need for recycling of this plastic. Since crude oil is
the starting material for the production of plastic, The reverse
of the process is possible. In this project, we have fabricated a
micro pyrolysis device to extract fuel from MELAMINE
FORMALDEHYDE commonly available as old Television
cabins. The characteristics like Flash point, Fire point, ,
Carbon Residue, Smoke point and viscosity of the PLASTIC
FUEL is calculated and the properties are compared with
Diesel. The fuel is then distilled by using ASTM Distillation
setup.

4. NEED FOR PROJECT
• To reduce plastic waste.
• To Reuse the waste plastic and extract fuel from it.
• To see the possibility to replace the non renewable energy sources.

5. PYROLYSIS OF PLASTICS
• Pyrolysis is the process of thermally degrading long chain
polymer molecules into smaller and less complex materials
through heat.
• Waste plastic is heated in an electrical reactor at a temperature of
about 350 - 400 ℃ provided with an inert atmosphere.
• The gases are then condensed in a Condenser (copper coil) by
circulating water.

6. BLOCK DIAGRAM
MAJOR PARTS
• ELECTRICAL REACTOR
• CONDENSER TANK
• COPPER COIL
• PUMP
• SUMP TANK
• CONTROL VALVE

7. ELECTRIC REACTOR
CATIA MODEL OF REACTOR

8. ELECTRIC REACTOR
REACTOR CYLINDER
Material : Mildsteel
Height : 450 mm
Outer dia : 410 mm
Inner dia : 370 mm
HEATER
Coating : Ceramic coated
Temperature : 400-500 ℃
Watts : 4000 watts
Voltage : 230v AC
Current : 1 Ф AC

9. CONDENSER
There are Two main parts in the condenser
1. Condenser Tank
For allowing the flow of water around the Condenser coil
2. Condenser Coil
For condensing the vapours produced by plastic in the Reactor

10. CONDENSER
CONDENSER TANK CATIA MODEL OF CONDENSER TANK

11. Width of the condenser = 460 mm
Height of the Condenser = 480 mm
CONDENSER TANK SPECIFICATIONS

12. COPPER COIL
CATIA MODEL OF COPPER COIL
CONDENSER COIL

13. Copper tube Diameter = 12.7 mm
Copper tube Length = 5186.6 mm
Coil Inner Diameter = 374.6 mm
Coil Outer Diameter = 400 mm
Number of turns = 5
COIL SPECIFICATIONS

14. SINGLE STAGE CENTRIFUGAL PUMP
SPECIFICATIONS
Speed = 2880 rpm
Head = 20 m

15. CATIA MODEL OF CONFDENSER TANK
SUMP TANK
SPECIFICATIONS
Length of the sump tank (L) = 1400 mm
Height of the sump tank (H) = 480 mm
Width of the sump tank (W) = 580 mm
Volume of the sump tank (V) = L * H * W
= 1400 * 480 *580
= 3.89 × 10^8 mm^3

16. CONTROL VALVE
FEATURES
• Tight shut off
• Minimum obstruction for the flowing
media
• High flow capacity
• Can withstand high temperatures and
pressures

17. ASSEMBLING

18. FINALASSEMBLY

19. EXTRACTED PLASTIC FUEL
For 6 kgs of plastic (Television
Cabins), We have obtained nearly
2 litres of Fuel

20. PROPERTIES OF EXTRACTED FUEL

21. SMOKE POINT
The maximum flame height in millimeters at which
plastic fuel or other volatile liquids fuels will burn
without smoking, When determined in the apparatus
and under specified conditions.
 The smoke point of extracted plastic fuel is 18mm

22. FLASH POINT AND FIRE
POINT
Flash Point
• Flash point is the lowest temperature at which on
application of test flame causes the material to
ignite and burn at least for 5seconds underspecified
conditions to the test.
Fire Point
• Fire point is the lowest temperature at which (fuel)
sample oil, On application of flame catches the fire
and burn continues.
 Flash point of Plastic fuel is 60oC
 Fire point of Plastic fuel is 70oC

23. CARBON RESIDUE TEST
The residue formed by evaporation and thermal
degradation of carbon containing material.
Crucible Weight, W1 = 21g
Crucible Weight with Oil, W2 = 23g
Crucible Weight with Residue, W3 = 21.5g
Weight of Oil, W2 - W1 = 2g
Weight of Carbon Residue, W3 - W1 = 0.5g
Percentage of Carbon Residue,
(W3 - W1)/(W2 - W1) = (0.5/2) * 100 = 25%

24. VISCOSITY MEASUREMENT
Viscosity
It is the resistance offered by a liquid to how when a
force is exerted on it.
• ρ = A * t – (B / t)
Where, t = time taken for 60ml flow of oil
• A = 2.24, B = 184 when 20 < t < 40
• A = 2.16, B = 60 when t > 40
Time taken for 60 ml flow of oil (t) = 4 sec
As the time taken for flow of 60 ml of oil does not
exceed the range (20 to 40 sec), We can conclude
that this Plastic Fuel has very less Viscosity.

25. ASTM DISTILLATION SETUP

26. PROPERTIES OF DISTILLED FUEL
• Initial boiling point of fuel = 120 oC
• Final boiling point of fuel = 164 oC
• Dry point of fuel = 190 oC

27. Comparison Chart of Plastic Fuel with Diesel
S.NO PROPERTY DIESEL [6] PLASTIC FUEL
1 Smoke Point 18 mm 18 mm
2 Flash Point 65℃ 60℃
3 Fire Point 78℃ 70℃
4 Carbon Residue 0.01 g 0.25 g
5 Initial boiling point 150℃ 120℃
6 Final boiling point 180℃ 164℃
7 Dry point 200℃ 190℃

28. MATERIAL COST
REACTOR 20,000
COPPER COIL 1500
PULMBING PARTS 2000
MILD STEEL 3000
GALVANIZED STEEL 1500
PAINT 500
PUMP 3000
TOTAL 31, 500
COST ANALYSIS

29. FUTURE SCOPE

30. SAVE NATURE SAVE US