Industrial Design Problem_1

To establish an efficient Pilot Plant Design to convert waste plastic to Fuel (energy).

TOPIC

Submitted By:~

Mohit Rouniyar

Mukul Anand Team Name:~ SPARX

Contents

Introduction

Plastics Analysis

Pre-treatment Process

Process Flow Diagram

Catalyst Analysis

Pyrolysis Reactor

Stimulation on Hysys

Material/Energy Balance

Economics Analysis

References

Waste Plastics To Fuel

Introduction

Plastics are synthetic organic materials produced by polymerization.

Waste plastics are one of the resources for fuel production because of its high heat of

combustion.

Plastics Type are Thermosetting, Thermoplastics,

Elastomer.

Most content of plastics are Polyethylene,

Polystyrene, Polypropylene, PVC, other.

Waste Plastics Analysis

Plastics and Petroleum derived fuels are Hydrocarbon

Plastics content longer carbon chains

Following Chart are comparison for calorific value of Petroleum products and Plastics

Material Calorific value (MJ/kg)

Polyethylene 46.3

Polypropylene

46.4

Polystyrene 41.4

Polyvinyl chloride 18.0

Coal 24.3

Liquefied Petroleum Gas 46.1

Petrol 44.0

Kerosene 43.4

Diesel 43.0

Heavy Fuel oil 41.1

Light Fuel oil 41.9

Block Diagram

Treatment of Impurities

Washing with Water for the removal of impurities like Sand, Mineral, Bio-Mass

Shredding of Waste Plastics for reducing the size

Drying for removal of waste water

Removal of Oxygen by introducing Purge Nitrogen Environment

Removal of Poly Vinyl Chloride after Pre Heating Process by the addition of NaOH

as solvent in scrubber

Removal of Benzoic Acid by De-chlorination

Pre Treatment Process

CATALYST ANALYSIS

Amorphous Almuino - Silicate is proposed

Meso - Structure having relatively low surface area

Pore size and Volume

Low Acid strength as compared to Zeolites.

Shows great activity on cracking of PP

Liquid fuel conversion is about 86%

The residual level is <8 wt % at 500°C.

Contd… YIELD(wt% FEED)

ZSM-5 USY MOR SAHA Silicates

PS PVC PS PVC PS PVC PS PVC PS PVC

Gases 4.25 30.64 3.84 28.11 1.85 31.07 0.72 30.29 0.05 34.49

Styrene 67.52 n.d 61.54 n.d 58.52 n.d 75.45 n.d 72.12 n.d

Other Aromatics

21.39 n.d 16.6 - 31.22 n.d 15.57 - 22.52 .

HCl n.d 54.52 n.d 55.87 n.d 55.52 n.d 55.45 n.d 56.2

Residue 6.84 14.81 18.02 16.02 8.41 13.41 8.26 14.26 5.31 9.31

n.d: Not Detectable

Stimulation Analysis

The composition of raw material (plastics) is PE:40%, PP: 40%, and PS: 20%.

Material balance of all streams are in steady state condition,

Vapors behave as ideal-gas and liquids behave as ideal-solution,

No accumulation of mass, and reaction only takes place inside the reactor, .

Enthalpy balance is based on the first law of thermodynamics

Work done on the system by its surrounding are zero.

Energy and Material balance data have been extracted from HYSYS 3.2 simulation

Process Flow Diagram

Overall Process Flow Diagram

Pyrolysis Reactor

Fluidized Bed Reactor

Proposed Material of Composition Stainless Steel

Addition of Duramunium and Mangnese

PROCESS HEATING RATE RESIDENCE

TIME

TEMPERATURE(°C) TARGET

PRODUCTS

SLOW

CARBONIZATION

VERY LOW DAYS 450-600 CHARCOAL

SLOW PYROLYSIS 10-100K/MIN 10-60 min 450-600 Gas, Oil, Char

FAST PYROLYSIS Upto 1000k/s 0.5-5s 550-650 Gas, oil, (char)

FLASH PYROLYSIS Upto 10000k/s <1 s 450-900 Gas, oil, (char)

Design of Pyrolysis Reactor

Product Analysis

Yield(w/w%) Polyethylene Polypropylene Polystyrene

Cracking Temperature

450°C 450°C 320°C

Gases 18.3 15.7 4

Liquids 81.7 84.2 93

Char >1 >0.25 3

Dominant Products

PE is n-alkenes,1-alkenes

PP is Cyclo-hexane

PS is Styrene

Chemical Reaction

Material Balances

Energy Balances

Economic Analysis

Type of Equipment Cost in USD($)

Storage Tank 1,713,600

Conveyor 977,300

Distillation Column 226,400

Total Estimation Cost 3,349,100

References

Wikipedia

Google

A text book on Chemical Reaction Engg by Octave Levenspiel

A text book of Chemical Technology by Dryden’s

Thesis paper on pyrolysis done by Feng Gao and many more.

…THANK S

?

Query

Robust Design