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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, MahatmaGandhi University College of Engineering, Thodupuzha, in partial fulfilment of therequirements for the award of the degree of Bachelor of Technology in Polymer Engineeringfrom 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: [email protected] 

    Mob: 9961161870

    3.  SANJAY R.

    MENASSERIL HOUSE

    C.M.C-1,

    CHER THALA P.O.

    ALAPUZHA-688524

    E- mail: [email protected] 

    Mob:- 9995069478

    4.  Swathi E.

    E-mail: [email protected]

    mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

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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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     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 retailstores and offices, are managed alone with other wastes from their sources and usuallycombined with household wastes. Special source of plastic waste is discarded agriculturemulch (film).

    Table 1: Plastics and their products

    Sl. No. Types of plastics Industries1 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 beconverted 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 andseparation 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 developmentis 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, knowledgeand 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 25 thSession 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, newmechanical 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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    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 andcertain 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

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    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

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      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

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    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 vinylidenechloride and fluro carbon

     polymers.

    Source of hazardous andcorrosive 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.

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    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 

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    4.3.4. NI TROGEN CYLI NDER

    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)

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    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

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    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 andtemperature 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.)

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    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.

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      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. Pa per 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 theexperiment)

      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

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    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:

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    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 vessel8.  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.

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    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 = TioC

    Final water temperature = Tf 0C

    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.

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    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

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    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

    dudy

    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 s ize

    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

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    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 400C (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.

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    A pycnometer also called specific gravity bottle, is a device used to determinethe 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.

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    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

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    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 valueis 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

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    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

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    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

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    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 

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    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

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    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

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    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

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    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

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    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 smallhydrocarbon 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.

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    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 Na nAlnSi96 – nO192·16H2O (0

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    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

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    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

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    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.

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    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. 

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    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

    http://www.sustainableplastics.org/http://www.sustainableplastics.org/http://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.chemtrust.org.uk/http://www.chemtrust.org.uk/http://www.chemtrust.org.uk/http://www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditiveshttp://www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditiveshttp://www.pvc.org/What-is-PVC/How-is-PVC-made/PVCAdditiveshttp://www.chemtrust.org.uk/http://www.tonto.eia.doe.gov/ask/crudeoil_faqs.asp#plasticshttp://www.sustainableplastics.org/

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     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

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    Certifications

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