Project report of (biodiesel extraction from waste plastic)

GOVERNMENT POLYTECHNIC COLLEGE
RAGHOGARH, GUNA (MP)
Project Report
On
“BIODIESEL EXTRACTION FROM WASTE PLASTIC”
Submitted in partial fulfilment of the requirement for the award of the
DIPLOMA IN ENGINEERING
In
MECHANICAL ENGINEERING
Submitted To
RAJIV GANDHI PROUDYOGIKI VISHWAVIDHYALAYA, BHOPAL
(M.P.)
Submitted By
o AKASH PRAJAPATI 14061M02003
o KISHOR KUMAR MANJHI 14061M02028
o AKASH BUNKAR 14061M02002
o CHANDRAMOHAN PRAJAPATI 14061M02012
o SACHENDRA SONI 14061M02051
o BHUPENDRA LODHA 14061M02011
o RAJKUMAR KIRAR 14061M02043
o RITESH JAKELE 14061M02049
Under the Supervision of
MR.RAJESH PATHORIYA
DEPARTMENT OF MECHANICAL ENGINEERING

2
GOVERMENT POLYTECHNIC COLLEGE
RAGHOGARH DISTT.GUNA
CERTIFICATE
This is to certify entitled being submitted by AKASH PRAJAPATI, KISHOR
KUMAR MANJHI, BHUPENDRA LODHA, AKASH BUNKAR,
CHANDRAMOHAN PRAJAPATI, SACHENDRA SONI, RITESH JAKELE,
RAJKUMAR KIRAR Student of final year in “MECHANICAL
ENGINEERING DEPARTMENT” has successfully completed the work entitled
“BIODIESEL EXTRACTION FROM WASTE PLASTIC”. This technical
project is hereby approved for submission towards partial fulfilment for the
diploma in Mechanical engineering From “Rajiv Gandhi Proudyogiki
Vishwavidyalaya, Bhopal.
MR.RAJESH PATHORIYA MR. K.R. DEHARIYA
(Project guide) (Principal)

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RAGHOGARH GUNA (MP)
APPROVAL SHEET
The major project entitled “BIODIESEL EXTRACTION FROM WASTE
PLASTIC” being submitted by AKASH PRAJAPATI, KISHOR KUMAR
MANJHI, BHUPENDRA LODHA, AKASH BUNKAR, CHANDRAMOHAN
PRAJAPATI, SACHENDRA SONI, RITESH JAKELE and RAJKUMAR
KIRAR has been examined by us and is hereby approved for the award of
diploma in “MECHANICAL ENGINEERING”, for which it has been submitted.
It is understood that by this approval the undersigned do not necessarily endorse or
approve any statement made, opinion expressed or conclusion drawn therein, but
approve the major project only for the purpose for which it has been submitted.
MR.RAJESH PATHORIYA
(Internal Examiner) (External Examiner)

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RAGHOGARH GUNA (MP)
SESSION 2016-2017
ACKNOWLEDGMENTS
We express our deepest gratitude to our principle Mr. K.R.Dheriya for providing
us with an environment to complete our project successfully.
We are deeply indebted to our Head of the Department Mr. Rajendra Kumar
Dixit and Mrs. Swati Goswami who modelled us both technically and morally for
achieving greater success in life. He showed us different ways to approach a
research problem and the need to be persistent to accomplish any goal .We thank
him heartily
We are very grateful to our Project Guide by Mr. Rajesh Pathoriya for being
instrumental in the completion of our project with his complete.
We also thank all the staff members of our college and technician for their help in
making this project a successful one.
Finally we take this opportunity to extend our deep appreciation to our family and
friends for all that they meant to us during the crucial of the completion of our
project.

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CONTANT
Topic No. Topic Name Page No.
 Abstract 07
 List Of Tables 08
 List of Figure 09
 Acronyms 10
01 Introduction 11
02 Target Waste Plastics 12
03 Process of fur Convention Waste Plastics into Fuel 14
3.1 Processing Material 14
3.2 Major equipment 14
3.3 Plastic purification Machine 14
3.4 Model of Convention Waste Plastics into Fuel 15
3.5 Application 15
3.6
General introduction of waste tire pyrolysis of biodiesel
production line
15
3.7 The Plastic2 Oil Advantage 16
04 Validation & Permitting 17
4.1 Processor 17
4.2 Inputs 17
4.3 Process 17
4.4 Resource Usage 17
4.5 Fuel Output 18
05 Liquid Fuel Production 19
5.1 Scope of liquid fuel in this compendium 19
5.2 Production method 19
5.3 Products and by-products 21

6
06 Liquid Fuel Production Examples 22
6.1
Environment System's commercial plant for liquid fuel
production
22
6.2
Mogami Kiko's commercial plant for liquid fuel
production
23
6.3 MCC's commercial plant for liquid fuel production 24
6.4 Altis's commercial plant for liquid fuel production 25
07 Liquid Fuel Production Examples 26
7.1
Toshiba's commercial plant for liquid fuel and Gas fuel
production
26
7.2 Technical description 27
08 Solid Fuel Production 28
8.1 Scope of solid fuel in this compendium 28
8.2.1 Large-scale model (3 ton/hour) 29
8.2.2 Small-scale model (150 kg/hour) 30
8.3 Product and by-product 32
09 Gaseous Fuel Production 33
9.1 Scope of gaseous fuel in this compendium 33
9.3 Product 34
10 Other Technologies 36
11 History 37
12 Feature Abstract 39
13 Conclusion 40
14 Reference 41

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ABSTRACT
Instead of installing a new waste plastic conversion facility, some of industrial
infrastructure provides optional methods for using waste plastics as fuels. Some use solid
prepared from waste plastics and other combustible wastes while others involve placing
the waste plastics into conversion equipment without pillarization.
The art of refining liquid hydrocarbons (crude oil) into diesel, and fuel oils was
commercially scaled decades ago. Unfortunately, refineries are technologically limited to
accepting only a very narrow range of liquid hydrocarbons with very specific properties
and minimal contaminates Unrecyclable, hydrocarbon-based waste is a significant
environmental problem in every year. According To the Environmental Protection
Agency’s 2010 Facts And Figures Report. Over 92% of waste plastic is not recycled and
with a growth rate of approximately 8% per year. There exists a critical need for a viable
and environmentally sound. General purpose hydrocarbon-based accepted refinery
standards have recycling process. Hydrocarbon streams that fall outside of traditionally
have been landfilled or melted into products of low value.
The barriers and challenges are so great that previous value. Unstable mixed fuels.
However, over the course of three years JBI, Inc. Has broken through these barriers and
has designed and wide of built a viable commercial-scale continuous refinery capable of
processing a hydrocarbon-based waste into specification fuels.
Research and testing of scale-up through 1-gallon, 3000 gallon, multi-kiln, and 40
ton day processors took place in a plant in Niagara Falls, NY. Technical challenges
encountered and lessons learned during process development will be explained in detail.
In 2009, our technology was “molecularly audited" by lsleChem, LLC of Grand
Island, NY and in 2012. the full-scale plant was viably validated by SAIC Energy,
Environment Infrastructure, and LLC Numerous sources of waste plastic and users of the
resulting products conducted extensive audits of the technology, process, and plant For
the purpose of this paper, processing of waste plastics will be discussed in detail;
however, this technology applied to other waste hydrocarbon-based materials such as
contaminated monomers, lubricants and other composite waste streams.
Introduction –
Early research in this field has primarily involved a number of batch-based
technologies, all with severe limitations properties, density, and pre-processing of waste
plastics impose significant limitations on batch-based .
Waste plastics have some of the most undesirable properties of any substance
when considered for thermal processing. Plastic have low-surface area, poor heat transfer,
and exceptional tensile strength and are considered an insulator. During the melting
process, plastics absorb heat and will stick to anything cooler, resulting in exigent “glue”
that will seize or bind some of the largest high-torque feed technologies.

8
LIST OF TABLE
Table
No.
Table name Page No.
01 List of Figure 09
02 Acronyms 10
03 Product types of some plastics pyrolysis 13
04 Typical properties of waste plastics derived fuel and petroleum 21
05
Environment System's commercial plant for liquid fuel
production
22
06 MICC's commercial plant for liquid fuel production 24
07 Altis’s commercial plant for liquid fuel production 25
08
Toshiba’s commercial plant for liquid fuel and Gas fuel
production
26
09 Heating values of various fuels and wastes 32
10 Wastes and typical products 34
11 Wastes and typical products 35

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LIST OF FIGURES
Fig No. Fig Name Page No.
Fig:-1 Plastic Purification Machine 14
Fig:-2 Model of Convention Waste Plastics into Fuel 15
Fig:-3 Production plant of plastics-derived fuel 20
Fig:-4 Schematic diagram of a typical plant 22
Fig:-5 Production plant in Yamagata Prefecture 23
Fig:-6 Fuel oil production system 24
Fig:-7 Plant for medical wastes 25
Fig:-8 Commercial plant for liquid and gaseous fuel production 26
Fig:-9 Schematic diagram a typical plant 27
Fig:-10 Example of RPF 28
Fig:-11 Example of pretreatment process (3 ton/h capacity) 29
Fig:-12 Schematic diagram of a pelletizing process 30
Fig:-13 Smaller RPF production facility Figure 31
Fig:-14 Heavy duty machine to feed wastes 31
Fig:-15 Production plant of plastics derive gaseous fuel 33

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ACRONYMS
ABS Acrylonitrile-Butadiene-Styrene copolymer
BTU British Thermal Unit
DTIE Division of Technology, Industry and Economics
GHG Green House Gas
IETC International Environmental Technology Centre
ISWM Integrated Solid Waste Management
JIS Japanese Industrial Standards
LNG Liquefied Natural Gas
LPG Liquefied Petroleum Gas
NGOs Governmental Organizations
PE Polyethylene
PET Polyethylene terephthalate
PF Phenol resin
PMMA Polymethyl metacrylate
POM Polyoxymethylene
PP Polypropylene
PS Polystyrene
PUR Polyurethane
PVA Polyvinyl Alcohol
PVC Poly vinyl-Chi ride
PVDC Polyvinylidene chloride
RDF Refuse Derived Fuel
RPF Refuse derived Paper and Plastic Fuel
3R Reduce, Reuse and Recycle
SRF Solid Recovered Fuel
UNEP United Nations Environment Programme

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1. Introduction
The process is really simple; it is similar to how alcohol is made. lf you heat
plastic waste in non-oxygen environment, it will melt, but will not burn. After it has
melted, it will start to boil and evaporate, you just need to put those vapors through a
cooling pipe and when cooled the vapors will condense to a liquid and some of the vapors
with shorter hydrocarbon lengths will remain as a gas. The exit of the cooling pipe is then
going through a bubbler containing water to capture the last liquid forms of fuel and
leave only gas that is then burned. If the cooling of the cooling tube is sufficient, there
will be no fuel in the bubbler, but if not, the water will capture all the remaining fuel that
will float above the water and can be poured off the water. On the bottom of the cooling
tube is a steel reservoir that collects all the liquid and it has a release valve on the bottom
so that the liquid fuel can be poured out. Here are some pictures to better understand the
design:
This device works on electricity (3 phase). It has s and consumes a total of 6kw
(1kw each coil). The coils are turned on and off by three solid state relays. one for each
phase, the relays are controlled by a digital thermostat with temperature sensor just a bit
below the lid, so that the vapour temperature can be monitored You need to heat the
plastic slowly to about 350 degrees and just wait till it does the magic Our device has a
capacity of 50 litres and can hold about 30 kg of shredded plastic process takes about 4
hours. but it can be shortened considerably by tweaking the design bit. As I said, this
makes a liquid fuel that can be used as multi fuel, that means it can be used on diesel
engines and also on gasoline engines, but we still need to test it will work on gasoline. It
works for diesel engines just fine, that has already been tested. There is a difference in
what plastic you use, if you use polyethylene (plastic cans, plastic foil, and all kind of
flexible non break plastics) you will get out liquid fuel that will solidify as it cools into
paraffin, it is still good for diesel engines as long as you use a heated fuel tank, because it
needs to be heated just about at 30 degrees Celsius to be liquid and transparent. If you
don't want that, you can put the paraffin through the device for one more time and you
will chop those hydrocarbons even smaller and half of the paraffin will turn to liquid fuel
and other half will remain a paraffin, but much denser and will melt at higher
temperatures, this is the stuff you can make candles out of and it does not smell at all
when burned maybe a bit li candles. But if you use polypropylene (computer monitor
cases, printer cases, other plastic only liquid fuel, no paraffin at all. All you need is just
filter is that break easily), you get out fuel out of solids and you good to go and put it in
your gas tank. We have made the analysis and it is almost the perfect diesel fraction. It
has no acids or alkaline in it, like fuel from tires does. The unit in the pictures can convert
about 60 kg of plastic into 60 litres of fuel in one day. Other methods of heating the
reactor can be employed, electricity is just easier to work with and control. Some
Japanese companies manufacture such devices, but their prices for unit is more than 100
000$, our home made device cost us 900$ max. We use aluminium oxide bricks to
insulate the heat, they are light as foam and can be easily cut in any shape, but any kind
of insulator can be used. The bricks make the highest costs for this device. It can also be
made using liquid fuel burners to heat the reactor. This will enable to make the device
self-sustainable by using about 10-15% of the produced fuel along with the produced.

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2. Target Waste Plastics
Waste plastics are one of the most promising resources for fuel production because of
its high heat of combustion and due to the increasing availability in local communities.
Unlike paper and Wood, plastics do not absorb much moisture and the water content of
plastics is far lower than the water content of biomass such as crops and kitchen wastes. The
conversion methods of waste plastics into fuel depend on the types of plastics to be targeted
and the properties of other wastes that might be used in the process. Additionally the
effective conversion requires appropriate technologies to be selected according to local
economic, environmental, social and technical characteristics.
The types of plastics and their composition will condition the conversion process and
will determine the pre-treatment requirements, the combustion temperature for the
conversion and therefore the energy consumption required. The fuel quality output, the flue
gas composition (e.g. formation of hazardous flue gases such as NOx and HCI), the fly ash
and bottom ash composition, and the potential of chemical corrosion of the equipment,
Therefore the major quality concerns when converting waste plastics into fuel
resources are
Follows:
i) Smooth feeding to conversion equipment: Prior to their conversion into fuel
resources, waste plastics are subject to various methods of pre-treatment to facilitate
he smooth and efficient treatment during the subsequent conversion process.
ii) Effective conversion into fuel products. In solid fuel production: thermoplastics act
as binders which form pellets or briquettes by melting and adhering to other non-
melting substances such as paper, wood and thermosetting plastics. Although wooden
materials are formed into pellets using a pelletizer, mixing plastics with wood or
paper complicates the pellet preparation process. Suitable heating is required to
produce pellets from thermoplastics and other combustible waste. In liquid fuel
production, thermoplastics containing liquid hydrocarbon can be used as feedstock.
iii) Well-controlled combustion and clean flue gas in fuel user facilities: It is important
to match the fuel type and its quality to the burner in order to improve heat recovery
efficiency. Contamination by nitrogen, chlorine, and inorganic species, for instance, can
affect the flue gas composition and the amount of ash produced. When using fuel prepared
from waste plastics, it must be assured that the flue gas composition complies with local air
pollution regulations
Classifies various plastics according to the types of fuel they can produce. It can be
observed that thermoplastics consisting of carbon and hydrogen are the most important
feedstock for fuel production either in solid or liquid form.
PE, PP and Ps thermos plastics are preferable as feedstock in the production of liquid
hydrocarbons. The addition of thermosetting plastics, wood, and paper to the feedstock leads
to the formation of carbons substances and lowers the rate and yield of liquid products.
Table : Product types of some plastics pyrolysis

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Main products Type of plastics As a feedstock of liquid fuel
Liquid hydrocarbons Polyethylene (PE)
Polypropylene (PP)
Polystyrene (PS)
Polymethyl methacrylate
(PMMA)
Allowed
Allowed
Allowed
Allowed
Liquid hydrocarbons Acrylonitrile-Butadiene-Styrene
copolymer (ABS)
Allowed But not suitable.
Nitrogen-containing fuel is
obtained, Special attention
required to cyanide in oil
No hydrocarbons
suitable
for fuel
Polyvinyl alcohol (PVA)
Polyoxymethylene (POM)
Not suitable, Formation of
water
and alcohol.
Not suitable Formation of
formaldehyde
Solid products Polyethylene Not suitable Formation of
terephthalic acid and benzoic
acid.
Carbons products Polyurethane (PUR)
Phenol resin (PF)
Not suitable.
Not suitable
Hydrogen chloride and
carbons products
Polyvinyl chloride (PVC)
Polyvinylidene chloride
(PVDC)
Not allowed

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3. Process of for Convention Waste Plastics into Fuel
3.1 Processing Material
 Waste tire, rubber.
 Polythene bags.
 Unused Buckets.
 In house use waste plastic toys and plastic bottles,
 Hospital used waste injection and plastic bottles.
 And any west plastic we can use.
3.2 Major equipment
 Tank reactor
 Re-boiler
 Condenser
 Pressure vessel
 Hydrocarbon oil
3.3 Plastic purification Machine
For out of the water soil, dust, unwanted material from plastic we do use the plastic
purifying machine and that machine do proper dry and cleaned of plastic before
going to the tank Reactor.
Fig 1 - Plastic purification Machine

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3.4 Model of Convention Waste Plastics into Fuel:-
Fig 2 Model of Convention Waste Plastic into Fuel
3.5 Application:
Renewable source of biodiesel extraction technology from waste tire and waste
plastic etc. gas. A small farm can use a device this huatai waste tire making biodiesel
machine p the most efficient biodiesel oil pyrolysis from waste tire, waste plastic and waste
the advanced designed biodiesel plant ensures high quality diesel and gasoline clear with
national standard, fulfilling using for motor vehicle. This superior biodiesel technology is
featured by low production cost, simple process and small environmental pollution, solving
problems of process of waste rubber, tire, and plastics.
3.6. General introduction of waste tire pyrolysis of biodiesel production line:
 Tire black oil ability. Waste tire or rubber is processed through sorting. Pyrolysis
crush, mix by spiral mixer in thermal cracking reactor, carbon black excluding.
Desulfurization or de-nitrification. Cracking, distillation column fractionation
until forming tire black oil.
 Dehydration, degumming and DE acidification. Heat tire oil for degumming and
dehydration, add sulphuric acid at temperature of 30-50 for acidification.
Separate precipitation, and remove acid sludge and gum.
 Washing, neutralization and decolonization. Wash 3-5 times, add 5s. Reagent of
sodium hydroxide caustic neutralization, waste lye and DE color with activated
clay.
 Filtration and di Filter the crude biodiesel by frame filter, catalytic distillation, add

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 Filtration and distillation. Filter the crude biodiesel by frame filter, catalytic
distillation; add other oil and catalysts to reconcile high quality biodiesel.
Featured characteristics of waste tire to pyrolysis biodiesel plant:
 Acid sludge and gum after DE acidification and precipitation can make
waterproof membrane.
 The neutralization of waste acid and alkali after washing can produce sodium
sulfate.
 The generated waste after activated clay blenching and filtration can be used as
fuel.
3.7. The Plastic20il Advantage
With its revolutionary plastic20il (p20) technology. Plastic20il Inc. has pioneered the
development of a process that derives ultra-clean, ultra-low sulphur fuel which does not
require further refining. Directly from unwashed, unsorted waste plastics. At Plastic20ilR
advocate environmental sustainability while energizing local economies through the creation
of green jobs we expect our P20 technology will transform management practices to redefine
the recycling landscape and how we recycle tomorrow and into the future.
Our P20 technology has successfully overcome significant barriers in the fuel industry. Some
of the key differentiators of our process are outlined below.

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4. Validation & Permitting
 Reputable independent labs have validated the P20 technology including IsleChem
(process engineering) and Conestoga-Rovers & Associates (emissions stack test).
 Plastic20il® has been issued all necessary permits to operate by the New York State
Department of Environmental Conservation (NYSDEC).
 Plastic20ild has been issued an exemption from Air Permitting in the state where the
first site will be located for the agreement with Rock-Tenn Company ("Rock-Tenn")
 Engineering report performed by SAIC validates and verifies the technology and
economics.
4.1. Processor
 The processor requires only 4.500 sq. ft. of operating space.
 Height requirement is approximately 20 ft.
 Highly automated: very low operator to processor ratio.
 Modular design allows for easy deployment.
4.2. Inputs
 The P20 processor accepts unwashed, unsorted waste plastics, optimal feedstock
includes polyethylene and polypropylene.
 The P20 process is permitted by the NYSDEC for up to 4,000 lbs. of plastic feedstock
per machine per hour at the Company's Niagara Falls. NY facility.
4.3. Process
 The conversion ratio for waste plastic into fuel averages 86%.
 Approximately 1 gallon of fuel is extracted from 8.3 lbs. of plastic.
 The processor uses its own off-gases as fuel (approximately 10-12% of process
output): minimal energy is required to run the machine.
 Approximately 2-4% of the resulting product is Petcock (Carbon Black), a high BTU
fuel.
 Emissions are lower than a natural gas furnace of similar size, and the quality of the
emissions improve with increased feed rates
4.4. Resource Usage
 The P20 processor is designed to use minimal amounts of external energy.
 As well as being the environment, this is also a significant factor in the commercial
viability of the process.
 Water is used for cooling only and usage is minimized through recycling the water in
a non-contact closed loop. The water is not in contact with the process itself, keeping
it clean and uncontaminated.
 Only 53 kWh electricity is required to run the fans, pumps and small motors. No
electricity is used in the transformation of the plastic to fuel.

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4.5. Fuel Output
 Fuel quality has been validated by multiple independent petro-chemical labs
including: Intertek, Petro Labs, Alberta Resource Council and Southwest Research
Institute.
 All shipments leaving the P20 plant in Niagara Falls are tested by the Company's
fully equipped internal fuel testing lab.
 Fuel is ready for sale upon completion of processing without the need for further
refinement.
 From a single processor the Company can produce a range of fuel products, without
further refining, including No. 2 Fuel (Diesel, Petroleum Distillate), No. 6 Fuel,
Naphtha, pet coke (Carbon Black), and Off-Gases to be used in the P20 process

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5. Liquid Fuel Production
5.1. Scope of liquid fuel in this compendium –
Liquid fuel within this compendium is defined as plastic-derived liquid hydrocarbons
normal temperature and pressure. Only several types of thermoplastics undergo the
decomposition to yield liquid hydrocarbons used as liquid fuel. PE, PP, and PS, are preferred for
the feedstock of the production of liquid hydrocarbons. The addition of thermos plastics, wood,
and paper to feedstock leads to the formation of carbons substance. It lower the rate and yields of
liquid products.
Depending on the components of the waste plastic being used as feedstock for
production, the resulting liquid fuel may contain other contaminants such as amines, alcohols
waxy hydrocarbons and some inorganic substances. Contamination of nitrogen, sulphur halogens
gives flu gas pollution. Unexpected contamination and high water contents lower the product
yields and shorten the lifetime of a reactor for pyrolysis Liquid fuel users require petroleum
substitutes such as gasoline, diesel fuel and heavy oil. In these fuels, various additives are often
mixed with the liquid hydrocarbons to improve burner or the engine performance. The fuel
properties such as viscosity and ash co should conform to the specifications of the fuel user's
burners or engines. No additives would be needed for fuel used in a boiler. A JIS technical
specification was proposed for pyrolytic oil generated from waste plastic for use as boiler and
diesel generator fuel (1 S 20025:20 li operators and a well-equipped facility are required due to
the formation of h flammable liquids and gases.
5.2. Production method –
The production method for the conversion of plastics to liquid fuel is based on the pyro
the plastics and the condensation of the resulting hydrocarbons. Pyrolysis refers to thermal
decomposition of the matter under an in gas like nitrogen.
For the production process of liquid fuel, the plastics that are suitable for the conversion
are introduced into a reactor where they will decompose at 450 to 550 C. Depending on the
pyrolysis conditions and the type of plastic used, carbon us matter gradually develops as
a deposit on the inner surface of the reactor. After pyrolysis, this deposit should be removed from
the reactor in order to maintain the heat conduction efficiency of the reactor.
The resulting oil (mixture of liquid hydrocarbons is continuously distilled once of the
waste plastics inside the reactor are decomposed enough to evaporate upon reaching the reaction
temperature. The evaporated oil is further cracked with a catalyst. The boiling point of the
produced oil is controlled by the operation conditions of the reactor, the cracker and condenser.
In some cases, distillation equipment is installed to perform fractional distillation meet the user's
requirements.
After the resulting hydrocarbons are distilled from the reactor, some hydrocarbons with
high boiling points such as diesel, kerosene and gasoline are condensed in a water-cooled
condenser. The liquid hydrocarbons are then collected in a storage tank through a receiver tank.
Gaseous hydrocarbons such as methane, ethane, propylene and butanes cannot be condensed and
are therefore incinerated in a flare stack. This flare stack is required when the volume of the
exhaust gas emitted from the reactor is expected to be large.

20
Fig 3 - Production plant of plastics-derived fuel
There may be variations in the feeding methods used depending on the characteristic of
the waste plastic. The easiest way is to simply introduce the waste plastics into the out any pre-
treatment. Soft plastics such as films and bags are often treated with a shredder and a melted (hot
melt extruder) in order to feed them into the reactor otherwise they would occupy a large volume
of the reactor.
There are also different types of reactors and heating equipment. Both kiln-type and
crew-type reactors have been proposed, while induction heating by electric power ha eloped as
an alternative to using a burner.
Due to the formation of carbonous matter in the reactor, which acts as a heat insul me
tank reactors the stirrer is used to remove the carbonous matter rather than for er the liquid
product of the pyrolysis is distilled, the carbonous matter is taken out h a vacuum cleaner or in
some cases reactors are equipped with a screw conveyor tom of the tank reactor to remove the
carbonous matter.
Operators should understand the relationship between the amount and composition of the
waste plastics as well as the operating conditions. Energy consumption and plant cost relative to
the plastic treatment capacity are the typical criteria for evaluating the performance by products.

21
5.3 Products and by-products
Liquid fuel is used in burners or engines as a substitute for liquid petroleum. Table
presents the properties of waste plastic-derived fuel and petroleum fuels. Samples A and B whole
distillate and middle distillate of waste plastic pyrolytic oil respectively considering the burner or
engine operating stability, it is possible to mix plastics-derive with petroleum fuel.
Table: Typical properties of waste plastics-derived fuel and petroleum fuels
Category Sample A
(Whole
distillate)
Sample B
(Whole
distillate)
Diesel Fuel Heavy Oil
Specific gravity (15 ), g/cm3
0.8306 0.8430 0.8284 0.8511
Flashing Point ( ) -18(PM) 68.0 (Tag) 69.0 (Tag) 64 (PM)
Kinetic viscosity (30 /50 ),
mm2
/s
1.041/- -/1.73 3.822/- -/2.29
Carbon residue on 10% bottoms;
wt%
- 0.85 0.01 0.46
Ash weight (%) 0.00 <0.001 - 0.006
Gross heating value (cal/g) 11294 10746 - 10708
Total chlorine (wt ppm) 47 10 < 11.6
Nitrogen (wt%) 0.14 0.033 - 0.015
Sulfur (wt ppm) 100 910 310 0.41%
Some plastics yield residual substances such as carbons matter and other inorganic matter
during pyrolysis. Carbons matter can be used as a feedstock for solid fuel. Aluminium foil
inorganic substances may be contained depending on the level of waste composition so suitable
management is required.
Pyrolysis of mixed plastics with nitrogen-containing plastics produces the corresponding
liquid fuel with nitrogen compounds, which in turn produces nitrogen oxide in the flue gas at
combustion. Similarly, liquid fuel derived from waste plastics containing chlorine will cause
corrosion to the reactor and burner and it will form hydrogen chloride and dioxins. Flue gas
treatment should therefore be considered to avoid the potential risks that those chemicals pose to
workers and local residents.

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6. Liquid Fuel Production Examples
6.1 Environment System's commercial plant for liquid fuel production
Main features
Feed
Processes
Main equipment
Special features
Main product
Thermoplastics waste
(excluding chlorine-containing plastics)
Pyrolysis
Tank reactor
Continuous feeding of scrap film by using an extruder.
Hydrocarbon oil
Image of a typical commercial plant
Fig 4 – Schematic diagram of typical plant
6.2 Mogami Kiko’s commercial plant for liquid fuel production

23
Fig 5 - Production plant in Yamagata Prefecture
Two tank reactors are installed at Mogami Kiko's facility. Mixed plastic containers
and packaging from household waste are thermally decomposed to produce 50 to 90 wt%
of hydrocarbon oil. When using mixed plastics of bulk density 300 kg/m3, the
performance 1.5 t per day per reactor.

24
6.3 MCC's commercial plant for liquid fuel production
Main features
Feed
Processes
Main equipment
Special features
Main product
Thermoplastics waste
Pyrolysis
Tank reactor
Induction heating for pyrolysis
Hydrocarbon oil
Fig 6 – Fuel Oil Production System
6.4. Altis's commercial plant for liquid fuel production

25
Main features
Feed
Processes
Main equipment
Special features
Main product
Mainly mixed plastics; current commercial
operation is for medical waste
pyrolysis
Tank reactor
Removable inner reactor vessel
Hydrocarbon oil
Fig 7 - Plant for medical wastes
Upon pyrolyzing chlorine-containing plastics, hydrocarbons and hydrogen chloride
formed. After removal of hydrogen chloride in a DE chlorination system, volatized
hydrocarbons are condensed with a condenser. The resulting liquid hydrocarbons are stored
in a service tank for use. Gaseous components are incinerated in a flare stack to yield a flue
gas without hydrocarbon contamination.

26
7. Liquid Fuel Production Examples
7.1 Toshiba’s commercial plant for liquid fuel and Gas fuel production
Main features
Feed
Processes
Main equipment
Special features
Main product
Thermoplastics waste and/or biomass
(excluding chlorine-containing plastics)
Pyrolysis
Rotary kiln with external heating
Continuous feeding
Fig 8 - Toshiba’s commercial plant for liquid fuel and Gas fuel production
7.2. Technical description

27
As shown in Figure 9, our system of thermal treatment for organic waste consists of a
hopper, feeder, rotary kiln, condenser, gas refiner, oil (gas) storage tank and dual fuel engine
generator.
Fig 9 – Schematic diagram of typical plant

28
8. Solid Fuel Production
8.1. Scope of solid fuel in this compendium
Solid fuel, as referred in this compendium, is prepared from both municipal and industrial
non-hazardous waste. Additionally, the solid fuel outlined here excludes coal and coal derived
fuels as well as solid biofuels such as firewood and dried manure but it may contain biofuels as a
component.
This compendium differentiates two types of solid fuel: refuse derived fuel (RDF), also
called solid recovered fuel (SRF) and refuse-derived paper and plastic densified fuel (RPF).
RDF is mainly produced from municipal kitchen waste, used paper, waste wood and
waste plastics. Due to the presence of kitchen waste, prior to the conversion to a fuel, a drying
process is required to remove the moisture from such waste to allow the solidification of the
waste in suitable shapes and densities. This process is seen as a disadvantage due to the large
amount of energy that the process requires. Solid recovered fuel (SRF) is defined in the
European Committee for Standardization technical specification (CEN/TS 15359:2006).
Fig 10 – Example of RPF

29
8.2 Production method
The solid fuel production process usually involves two steps, pretreatment and pellet
Production:
 Pretreatment includes coarse shredding and removal of non-combustible materials.
 Pellet production comprises secondary shredding and pillarization (<200°C)
Two types of commercial production systems are described as follows. One is a large-scale
model with pretreatment for the separation of undesirable contamination such as metals and
plastics containing chlorine. The other is a small-scale model without pretreatment equipment.
8.2.1 Large-scale model (3 ton/hour)
Industrial waste plastics, which have been separated and collected in factories, are ideal
to be used for solid fuel production. A fuel production facility consists of a waste unloading area,
stockyard, pretreatment equipment, pelletizing equipment and solid fuel storage. The
pretreatment process includes crushing and sorting for the removal o unsuitable materials from
incoming wastes. Schematic diagram of the pretreatment process is shown in Figure 11 presents
a photograph of a pretreatment process.
Fig 11 – Example of a pretreatment process (3 ton/h capacity)

30
After pretreatment, a suitable mixture of paper and plastics are further processed in a secondary
crusher and sorting process (conveyor and magnetic separator) and the resulting mixture is
pelletized to produce solid fuel. The resulting solid fuel is cooled in an air-cooling system to
prevent natural ignition during storage and it is further stored for shipping. The output of the
process is usually solid fuel pellets of dimensions between 6 to 60 mm in diameter and 10 to 100
mm in length. The heating value of the pellets will change depending on the content of the
plastics. A mixture of paper and plastics of a 1:1 weight ratio gives a heating value of
approximately 7,000kcal/kg or higher. Figure 12 shows a pelletizing process.
Fig 12 - Schematic diagram of a pelletizing process
8.2.2 Small-scale model (150 kg/hour)
This small-scale model is a system for solid fuel production with a 150 kg/h capacity. In
case the facility does not have a pretreatment process, (as aforementioned, a sorting process is
not required if properly segregated waste can be collected) so the combustible wood, paper and
plastic waste is directly fed into the crusher of the facility. This is carried out by using a handling
machine as shown in Figure 14 where the operator must control and feed into the crusher a
suitable ratio of each type of waste in order to maintain the fuel qualities such as the heating
value. After crushing the materials, they are transported thro pipe conveyor and are introduced
into a twin-screw pelletizer.
Figure 13 shows the entire process (the crusher, the pipe conveyor and the pelletizer.)

31
.
Fig 13 – Smaller RPF production facility Figure (150 kg/h)
Fig 14 – Heavy duty machine to feed wastes

32
8.3 Product and by-product
Heating value is an important characteristic of solid fuels. Some examples of heating
values of several types of waste and solid fuel are listed in.
Table: Heating values of various fuels and wastes
Fuel or waste Typical heating value (kcal/kg)
RDF 4000 5000 *1
RPF 6000-8000*2
Coal 6000 8000 *3
Heavy oil 9500
Wood paper 4300
Plastics (polyethylene) 11000
Typical municipal waste 1000-1500 *1
1. Depends on waste composition.
2. Can be controlled by plastic composition in fuel production processes.
3. Depends on rank of coal
The heating values of solid RDFs and RPFs may vary depending on the composition of
the materials they contain. Especially in RDF, fluctuations in the heating values are often
observed due to changes in the composition of the municipal waste (which is difficult to control)
and according to the degree of drying of the municipal waste used in the production process.
RPF heating values can usually be controlled easily due to the use of dry and sorted plastics,
paper and other combustible waste, which have been collected from companies.
Other important features of the solid fuels are its content of ash. Moisture and the content of
potential hazardous substances like nitrogen, chlorine, sulfur and heavy metals.
Fuel suppliers should have an agreement with fuel users regarding the solid fuel qualities Special
attention is required in order to avoid self ignition and methane evolution during the RDF storage
9. Gaseous Fuel Production

33
9.1 Scope of gaseous fuel in this compendium
The gaseous fuel described in this report refers to the flammable gas obtained from the thermal
treatment of waste plastics. There are two types of gaseous fuel:
 Gaseous hydrocarbon: hydrocarbons that are in a gaseous state under normal
temperature and pressure (0 , 1 atm)
 Synthesis gas or syngas: mixture of hydrogen and carbon monoxide
In the conversion of plastics to gaseous fuel, the waste plastics undergo thermal
decomposition in a tank reactor, resulting in the formation of liquid fuel as the main product and
gaseous fuel up to about 20 wt%, as the minor product. Gaseous hydrocarbons become the main
product after residing in the reactor for an extended time at a reaction temperature under
controlled decomposition conditions and the use of a specific reactor, Under specific conditions,
carbon and carbohydrates can be used as feedstock’s for the production of gaseous fuel like
methane and hydrogen.
9.2 Production method
The gasification process includes a series of steps such as pretreatment, gasification, gas cleaning
and storage
Fig 15 - Production plant of plastics-derived gaseous fuel
Polyethylene and polypropylene thermally decompose at temperatures up to about 700 and
under a inert atmosphere to form a mixture of gaseous hydrocarbons, methane, ethane, ethylene,
propane, propylene, and various isomers of butane and butane. On the other hand, Most of the
organic substances undergo gasification yielding syngas.

34
Gasification proceeds at elevated temperatures, higher than 800 and practically 1000 .
Depending on the types of reactors and reaction conditions, carbons matter and carbon dioxide
are formed, and nitrogen from the air is contained in the product gas.
The gasification reactors to be used are moving-bed, fluidized-bed and entrain-bed reactors. If
the product is to be stored, a large gas holder is to be required.
The gasification technique is already used commercially for coal and there are several examples
of commercial operations using biomass and waste plastics to produce low- and medium-BTU
gas.
Several manufacturers have proposed small-scale gasification systems. Careful cost analysis is
important with respect to the amount of collected waste, the transportation distance and the
commercial value of the resultant products such as electricity and gaseous fuel.
In any case, this technology requires skillful operators and careful handling to avoid hydrogen
explosion
summarizes the gasification methods which yield flammable gas
Table: List of various gasification methods
Type of gasification Conditions Typical products
Pyrolysis >700 under inert
atmosphere
Gaseous hydrocarbons from aliphatic
hydrocarbons including polyethylene
and polypropylene
Partial oxidation >1000 under oxygen
or air
Carbon monoxide from carbon,
Hydrocarbons and carbohydrates
including wood. Hydrogen also forms
from hydrocarbons and
carbohydrates.
Steam gasification >800 under oxygen or
air
Methane, carbon monoxide and
hydrogen
Hydrogasification Around 500 600
Hydrogen
Methane, carbon monoxide and water
9.3 Product
As afore mentioned, there are two types of pyrolysis products in the gasification process.
One is a mixture of gaseous hydrocarbons such as methane and ethylene while the other is
synthetic gas a mixture of hydrogen and carbon monoxide. Table 5.2 shows the type of waste
and its typical products. For specific types of plastics, compaction and volume reduction can also
be important. Volume reduction of expanded polystyrene is performed by thermal melting or by
a solvent dissolution method. The resulting ingot is a raw material for recycled resin production.
Such pretreatment technologies contribute to the reduction of transport costs and improvement of
processing efficiency by increasing the feeding rate. Similarly, granulation of plastics such as
films and bags using a granulator can be an essential tool to improve transport efficiency, feeding
to equipment and processing.
Table: Wastes and typical products

35
Type of waste Pyrolysis
conditions
Typical products
Polyethylene, polypropylene Inert atmosphere,
700 -800 °C
High-BTU gas (e.g. 9000 kcal Nm3):
Hydrocarbon gas like Methane and
ethylene. Liquid hydrocarbon like
benzene and toluene.
Aromatic polymer, carbons
substances carbohydrates
like wood in addition to the
Polymers above.
Air, steam
atmosphere
above 1000 °C
Low-BTU gas (e.g. 800-1800
kcal/Nm3); Hydrogen, carbon
monoxide, carbon dioxide and nitrogen.
Methane formation increases the heating
value to give medium-BTU gas.
The heating values of the gaseous products will vary according to the type of waste used.
the contamination of nitrogen from the air and/or other reasons. However it can be said that the
calorific value of Syngas ranges between the calorific value of biogas and LNG/LPG
10. Other Technologies
Instead of installing a new waste plastic conversion facility, some types of industrial
infrastructure provide optional methods for using waste plastics as fuels. Some use solid fuel
prepared from waste plastics and other combustible wastes while others involve placing the

36
waste plastics into conversion equipment without polarization. some applications in the steel,
lime and cement manufacturing industries are as follows: the steel industry, some countries
commercially treat waste plastics in blast furnace and coke ovens. Pioneering work has been
done in the area of blast furnace treatment in the UK d Germany3. Currently, some steel
manufacturers adopt similar treatment methods4. The y aspects of the technology are the
preparation of the waste plastics pellets at a constant and subsequent injection of the pellets into
a blast furnace. Contamination by chlorine-containing plastics and some other materials is
prohibited in order to prevent any verse effects to the steel.
Lime is used for steel production and solid fuel from waste plastics is used as fuel in lime
kilns. Preparation of solid fuel (RPF) with a heating value of 8000 kcal/kg and a method for
injecting it into a kiln have been developed and commercially utilized in Japan.
In cement production, shredded waste plastics are injected into a cement kiln for use a el.
Chlorine-containing plastics should be removed prior to the injection so as to maintain cement
quality 5.
All around the globe companies and individuals are starting to produce fuel from was plastic. As
only 8% of waste plastic is recycled in the U.S., 15% in Western Europe, and much less in
developing countries, this reuse of plastic could potentially keep enormous amounts of plastic
out of landfills and out of the oceans. Over 500 billion pounds of ne plastic is manufactured each
year and roughly 33% of that is single use and thrown away. A so little plastic is recycled, we
need to reframe plastic waste as an underused resource vs landfill destined. If all plastic waste
made it into the landfill, it would surely be mined in the future, but currently all plastic waste
does not make it into our landfills. The United Nation estimates plastic accounts for four-fifths of
the accumulated garbage in the world's oceans We need to stop polluting our oceans with plastic
before it is too late, and start collecting plastics suitable for this new fairly simple technology, a
technology that is available now
11. History
The technology is not overly complicated; plastics are shredded and then heated in
oxygen-free chamber (known as pyrolysis) to about 400 degrees Celsius. As the plastics biogas
is separated out and often reused to fuel the machine itself. The fuel is then distilled a filtered.

37
Because the entire process takes place inside a vacuum and the plastic is melted n burned,
minimal to no resultant toxins are released into the air, as all the gases and or sludge are reused
to fuel the machine.
For this technology, the type of plastic you convert to fuel is important. If you burn pure
hydrocarbons, such as polyethylene (PE) and polypropylene (PP), you will produce a fuel that
burns fairly clean. But burn PVC, and large amounts of chlorine will corrode the react and
pollute the environment. Burning PETE releases oxygen into the oxygen deprive chamber
thereby slowing the processing, and PETE recycles efficiently at recycling canters so it is best to
recycle PETE traditionally. HDPE (jugs) and LDPE (bags and films) a basically polyethylene so
usable as fuel as well, just slightly more polluting as a thick heavier fuel is created. But
additional processing can turn even HDPE into a clean diesel.
“Polyethylene and polypropylene are pure hydrocarbons, only they are arranged in long chains.
If you chop those chains into shorter ones, you get oil, if you chop them even shorter you get
diesel, and if you chop them again you get gasoline and eventually burnable gas.”
In Niagara Falls, NY, John Bordynuik's "Plastic Eating Monster can even vaporize thick
HDPE plastic into a cleaner burning number 2 fuel. Put plastic in end of the machine and out the
other end comes diesel, petroleum distillate, light naphtha and gases such as methane, ethane,
butane and propane. The machine accepts unwashed, unsorted waste plastics, composites and
commingled materials and returns about 1 gallon of fuel from 8.3 pounds of plastic. And the
processor uses its own off-gases as fuel, therefore using minimal energy to run the machine. John
currently has two massive steel processors up and running, with financing secured for three more
to be built in the very near future.
In the Philippines, Poly-Green Technology and Resources Inc. was started by Jayme
Navarro whose sister asked him to come up with a way to recycle plastic bags. A plant is being
built that will produce 5,000 kilos of fuel per day. www.polygreen.com.Ph
Cynar in the UK likes to call their product 'End of Life Plastic to Diesel' or ELPD. Their
technology converts mixed Waste Plastics into synthetic fuels that are cleaner, low in sulphur
and in the case of the diesel, a higher cetane than generic diesel fuel. They have a plant running
in Ireland, with another to open in Bristol, UK in January and many more in the planning stage.
Each Cynar plant can process up to 20 tons of End of Life Plastic per Home
The art of refining liquid hydrocarbons (crude oil) into dies gasoline, and fuel oils was
commercially scaled decades ago. Unfortunately, refineries are technologically limited to
accepting only a very narrow range of liquid hydrocarbons with very specific properties and
minimal contaminates. Unrecyclable, hydrocarbon-based waste is a significant environmental
problem increasing every year. According to the Environmental Protection Agency's 2010 facts
and Figures report, over 92% of waste plastic is not recycled and with a growth rate of
approximately 8% per year, there exists a critical need for a viable and environmentally sound,
general purpose hydrocarbon-based recycling process. Hydrocarbon streams that fall outside of
accepted refinery standards have traditionally been landfilled or melted into products of low
value.
The barriers and challenges are so great that previous attempts to refine waste plastics
into fuel resulted in unviable batch-based machines producing low-value, unstable mixed fuels
However, over the course of three years JBI, Inc. ("JBI) has broken through these barriers and
has designed and built a viable commercial-scale continuous refinery capable of processing a
wide-range of hydrocarbon-based waste into ASTM specification fuels.

38
Research and testing of scale-up through 1-gallon, 3000 gallon, multi-kiln, and 40
ton/day processors took place in a plant in Niagara Falls, NY. Technical challenges encountered
and lessons learned during process development will be explained in detail
In 2009, our technology was molecularly audited" by IsleChem, LLC (“IsleChem") of
Grand Island, NY and in 2012, the full-scale plant was viably validated by SAIC Energy
Environment & Infrastructure, and LLC ("SAIC"). Numerous sources of waste plastic and users
of the resulting fuel products conducted extensive audits of the technology, process, and plant.
For the purpose of this paper, processing of waste plastics will be discussed in detail: however,
this technology can be applied to other waste hydrocarbon-based materials such as contaminated
monomers, waste oils, lubricants and other composite waste streams,
Introduction
Early research in this field has primarily involved a number of batch-based techno severe
limitations. Properties, density, and preprocessing of waste plastic impose significant limitations
on batch-based units.
Waste plastics have some of the most undesirable properties of any substance when
considered for thermal processing. Plastics have low-surface area, poor heat transfer, and
exceptional tensile strength and are considered an insulator. During the melting s absorb heat and
will stick to anything cooler, resulting in exigent "glue" or bind some of the largest high-torque
feed technologies.
A common extruder utilizes a 300hp motor to liquefy 500kg/hr. of plastics already
preprocessed into pellets (Worner, 2011). Due to the cost of extrusion as well as vapour issue
prior technologies opted for a batch design with feeding only when a reactor is cold.

39
12. Feature abstract
As we know that in real feature these resources like petrol and diesel are going too
exhausted. As per the American society in petrol of about 100 years, there will be great shortage
of crude oil due to no fossil left under the earth. In present countries like UAE, IRAN and IRAQ
etc. are most abundant in crude oil, frit, due to increasing population, these resources are going to
end up in few years this sear city of crude oil is going to affect India the most because is a time
of approx. 15 years, India is going to become the most populated country and the transportation
will increase, this increase in transportation will impose on also increased requirement of fossil
fuels.
To solve this problem, we can adopt this method of synthesizing diesel it to the simplest
way for synthesizing diesel This method will not create any diversity of diesel in feature India is
the country where about 2000 tons of plastic is every day If this plastic will use for making
diesel. a day may come when these will be no need for purchasing diesel from other countries
Plastic will get decomposed acts plastic decomposition is a series issue Pollution will be reduced
polythene bag will be not needed to be banned by the government. Diesel will be approval at low
prize; chances for employment will increase infection will be lowered.
The main problem of India, i.e. unemployment will be solved because establishment of
biodiesel plant will provide employment and that money India spent in foreign investment will
be saved and will be utilized for common people.

40
13. Conclusion
The primary goal of this project by able to apply the technical knowledge gainedand in
the conversion methods waste plastics into fuel depend on the types of plastics to be targeted and
the properties of other wastes that might be used in the process. Additionally the effective
conversion requires appropriate technologies to be selected according to local economic,
environmental, social and technical characteristics additives such as flame retardants containing
bromine and antimony compounds or plastics containing nitrogen, halogens, sulfur or any other
hazardous substances.
The whole process plant was thoroughly studied and thus we were able to appreciate the role
actor in the model. While the model out that how a piece of land is optimally utilized while
constructing a plant. The problems that usually arise due to negligence, their reasons and the
respective consequences were visualized which highlighted importance of safety in amodel.

41
14. Reference
 www.earthtechnica.com
 www.polygreen.com
 www.plastic2oil.com
 www.energeticforum.com

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