TITLE OF THE PROJECT

WASTE PLASTIC PYROLYSIS

PROJECT REFERENCE NO.: 39S_BE_0707

COLLEGE : BLDEA College of Engineering and Technology, Vijaypur.

BRANCH : DEPARTMENT OF CIVIL ENGINEERING

GUIDE : Prof. A.S. Tanksali

STUDENTS : Mr. Runal Desai

Mr. Hannan Ahmed

Mr. Sachin Pawar

Mr. Basavaraj Balkunde

INTRODUCTION : Attached Below

OBJECTIVE: Attached Below

METHODOLOGY: Attached Below

CONCLUSION: Attached Below

FUTURE WORK: Attached Below

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SYNOPSIS

The present rate of economic growth is unsustainable without saving of fossil energy like crude
oil, natural gas, or coal. There are many alternatives to fossil energy such as biomass,
hydropower, and wind energy. Also, suitable waste management strategy is another important
aspect. Development and modernization have brought about a huge increase in the production of
all kinds of commodities, which indirectly generate waste. Plastics have been one of the materials
because of their wide range of applications due to versatility and relatively low cost.

Some 299 million tons of plastics were produced in 2013, representing a 4 percent increase
over 2012. Recovery and recycling, however, remain insufficient, and millions of tons of plastics
end up in landfills and oceans each year
Approximately 10–20 million tons of plastic end up in the oceans each year. A recent study
conservatively estimated that 5.25 trillion plastic particles weighing a total of 268,940 tons are
currently floating in the world’s oceans.
And since plastic being a non-biodegradable material it remains into the soil, thereby polluting
the environment.
Our Project deals with the extraction of OIL/DIESEL from the waste plastics termed as
PLASTIC PYROLYZED OIL which can be marketed at much cheaper rates compared to that
present in the market. As we know that both Plastics and Petroleum derived fuels are
Hydrocarbons that contain the elements of Carbon & Hydrogen. Pyrolysis process becomes an
option of waste-to-energy technology to deliver bio-fuel to replace fossil fuel. The advantage of
the pyrolysis process is its ability to handle unsort and dirty plastic. The pre-treatment of the
material is easy. Plastic is needed to be sorted and dried. Pyrolysis is also non toxic or non
environmental harmful emission unlike incineration.

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CHAPTER: 01
INTRODUCTION

Due to the fossil fuel crisis in past decade, mankind has to focus on developing the
alternate energy sources such as biomass, hydropower, geothermal energy, wind energy, solar
energy, and nuclear energy. The developing of alternative-fuel technologies are investigated to
deliver the replacement of fossil fuel. The focused technologies are bio-ethanol, bio-diesel lipid
derived bio-fuel, waste oil recycling, pyrolysis, gasification, dimethyl ether, and biogas. On the
other hand, appropriate waste management strategy is another important aspect of sustainable
development since waste problem is concerned in every city.

The waste to energy technology is investigated to process the potential materials in waste
which are plastic, biomass and rubber tire to be oil. Pyrolysis process becomes an option of
waste-to-energy technology to deliver bio-fuel to replace fossil fuel. Waste plastic and waste tire
are investigated in this research as they are the available technology. The advantage of the
pyrolysis process is its ability to handle un-sort and dirty plastic. The pre-treatment of the material
is easy. Tire is needed to be shredded while plastic is needed to be sorted and dried. Pyrolysis is
also no toxic or environmental harmful emission unlike incineration

Economic growth and changing consumption and production patterns are resulting into rapid
increase in generation of waste plastics in the world. For more than 50 years the global production
of plastic has continued to rise.

Some 299 million tons of plastics were produced in 2013, representing a 4 percent increase
over 2012. Recovery and recycling, however, remain insufficient, and millions of tons of plastics
end up in landfills and oceans each year

Approximately 10–20 million tons of plastic end up in the oceans each year. A recent study
conservatively estimated that 5.25 trillion plastic particles weighing a total of 268,940 tons are
currently floating in the world‟s oceans.
And since plastic being a non-biodegradable material it remains into the soil, thereby
polluting the environment.

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On the other hand, appropriate waste management strategy is another important aspect of
sustainable development since waste problem is concerned in every city. As we know that both
Plastics and Petroleum derived fuels are Hydrocarbons that contain the elements of Carbon &
Hydrogen. Pyrolysis process becomes an option of waste-to-energy technology to deliver bio-fuel
to replace fossil fuel. The advantage of the pyrolysis process is its ability to handle unsort and
dirty plastic. The pre-treatment of the material is easy. Plastic is needed to be sorted and dried.
Pyrolysis is also no toxic or non environmental harmful emission unlike incineration.

Fig. 1
The above graph shows the plastic generation and the amount of plastic that
is subjected to recycling.

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Disposal methods of waste plastics & their advantages and

disadvantages:

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CHAPTER: 02
OBJECTIVES

The main objectives of this project are:

1. To establish the basis for the development and implementation of waste plastics recycling with
the application of environmentally sound technologies (EST) to promote resource conservation
and green house gases (GHG).
2.
To raise awareness in developing countries like INDIA on plastic waste and its possible reuse for
conversion into diesel or fuel, this could be generated and marketed at cheaper rates compared to
that of the available diesel or oil in the market.
3.
To reduce the dependency on gulf countries for fossil fuels, thereby contributing to the Economic
growth of the country.

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CHAPTER: 03
LITERATURE SURVEY

1. M.fAli reported that the high yields of liquid fuels in the boiling range 100°C–480°C and gases
were obtained along with a small amount of heavy oils and insoluble material such as gums and
coke. The results obtained on the co-processing of polypropylene with coal and petroleum
residues are very encouraging as this method appears to be quite feasible to convert plastic
materials into liquefied coal products and to upgrade the petroleum residues and waste plastics.

2. Miskolczi Investigated the pyrolysis of real waste plastics (high-density polyethylene and
polypropylene) in a pilot scale horizontal tube reactor at 520 °C temperature in the presence and
absence of ZSM-5 catalyst. It was found that the yields of gases, gasoline and light oil could be
increased in the presence of catalyst. They also concluded that the plastic wastes could be
converted into gasoline and light oil with yields of 20–48% and 17–36% respectively depending
on the used parameters.

3. F murfyk from the recent literature, it is evident that the process of converting waste plastic to
reusable oil is a current research topic, preparation of blends of diesel with varying proportions of
waste plastic oil produced from the thermal pyrolysis and the analysis of viscosity and density of
these blends is presented. The feasibility of the waste plastic oils derived from PVC plastics as an
alternate fuel for transportation is also checked by conducting performance test on a single
cylinder Kirlosker diesel engine equipped with electrical loading at 50% of the engine maximum
load i.e., at 3.7 kW.

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CHAPTER: 04
TYPES OF PLASTICS AND ITS PROPERTIES AND USES

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CHAPTER: 05
CHARACTERISTICS OF PLASTICS AND OIL PRODUCTS

Before looking at the process options for the conversion of plastic into oil
products, it is worth considering the characteristics of these two materials, to identify where
similarities exist, and the basic methods of conversion. The principal similarities are that they are
made mostly of carbon and hydrogen, and that they are made of molecules that are formed in
„chains‟ of carbon atoms.

Crude oil is a complex mixture of hydrocarbons, which are separated and

purified by distillation and other processes at an oil refinery. The majority of the crude oil is used
for the production of fuels for transportation, heating and power generation. These oil products
are not single components, but are a blend of components used to meet the relevant fuel
specifications in the most economic manner, given the composition of the crude oil and the
configuration of the oil refinery. These components have a wide range of chain lengths: gasoline
has compounds with a chain length of between three and 10 carbon atoms, and diesel has
compounds with a chain length of between five and 18 carbon atoms, but both contain only
hydrogen and carbon.

Plastic is a generic term for a wide range of polymers produced using

highly refined fractions of crude oil, or chemicals derived from crude oil, known as monomers.
Polymers are formed by the reaction of these monomers, which results in chain lengths of tens or
hundreds of thousands of carbon atoms. Some polymers also contain oxygen (e.g. polyethylene
terephthalate (PET)), whereas others contain chlorine (polyvinyl chloride (PVC)). It is worth
noting that only a small proportion (< 5%) of the crude oil processed in the world is used to
produce the monomers (e.g.ethane,propene) used in the manufacture of polymers (e.g.
polyethene, polypropylene).

The similarity between oil products and plastics is illustrated in Figure 2 . The figure
demonstrates where the atomic composition in most plastics is similar to those in gasoline and
diesel derived from crude oil.

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Fig. 2

Fig. 3

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CHAPTER: 06
METHODOLOGY

1.Identification of waste plastics. (PE/PP/PS/LDPE/HDPE)

2.Subjecting the waste plastic for pyrolysis process.
3.Condensation of the gas to obtain raw fuel.
4.Conversion of raw fuel into its pure form (diesel etc) by the process of distillation.

6.1. COLLECTION & IDENTIFICATION OF WASTE PLASTIC :

Fig. 4

The collection of waste plastic is quite an easy task as compared to other wastes , the plastic
wastes are abundant and can be obtained in large quantities from the households, roadsides,
hospitals, hotels etc.

Fig. 5

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Fig. 6

This plastics are usually termed as

POLYETHYLENE (PE)
POLYPROPYLENE (PP)
HIGH DENSITY POLYETHYLENE (HDPE)
LOW DENSITY POLYETHYLENE (LDPE)

Usually they are manufactured in the form of plastic bags, saline bottles, plastic tools,
chairs and other components which we usually come across in our day to day life.These plastics
could be collected or usually purchased at Rs.10 to 15/kg after being shredded and washed
properly.

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6.2. SUBJECTING THE WASTE PLASTIC FOR PYROLYSIS PROCESS:

Fig. 7

The pyrolysis is a simple process in which the organic matter is subjected to higher temperature
about 300ºC to 500ºC in order to promote thermal cracking of the organic matter so as to obtain
the end products in the form of – liquid, char and gas in absence of oxygen.

6.2.1. WHY WE ADOPT PYROLYSIS PROCESS:

Comparison of Green House Gas (GHG) Emissions by Pyrolysis process with other processes:
[11]

 Emissions associated with manufacture of other raw materials (excluding the waste plastic
stream) are 13.0kgCO2. For the case of pyrolysis these are owing to hydrogen that is consumed
within the process.

Site emissions from incineration of pyrolysis gases, distillation residues and 3% of the diesel
product generated are 56kgCO2
 Emissions associated with all elements of transport (products and waste) are 197kgCO2
 Based on these figures the emissions associated with pyrolysis are 266kgCO2
 Displacement savings associated with replacing fossilised diesel production are 426kgCO2.
 Overall the net emissions for pyrolysis are –160kgCO2.

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6.2.2 GHG emissions for different disposal process:

Fig. 8

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6.2.3. SETUP FOR TRIAL EXPERIMENT:

Fig. 9
Experimental setup of trial test conducted, wherein 380 grams of plastic was dumped into a
closed container and heated.

Fig. 10

Semi liquid fuel obtained after burning the waste plastic, which can be further processed into
diesel.

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Fig. 11
Efficient burning of the obtained fuel with a clear blue flame and minimum emission of CO2.

6.2.4. EXTRACTION PROCESS IN A SPECIALLY DESIGNED

MOULD(PYROLYZER):

The below picture shows the mould prepared by us so as to serve as a pyrolyzer device.

Fig. 12

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6.2.5. DESIGN DETAILS OF THE INSTRUMENT

 Material = Stainless Steel

 Top diameter = 25 cm
 Bottom diameter = 25 cm
 Depth = 40 cm
 Volume = 19634 cm
3

 Diameter of outlet = 2.54 cm

 Weight of mould = 14 kg
 Digital thermometer (upto 2000°C)
 Silicon visor

Fig. 13

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Fig. 14

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6.3. CONDENSATION OF GAS TO OBTAIN RAW FUEL:

After heating the waste plastic at a temperature of about 300 0C to 500 0C in the pyrolyzer
the gas is allowed to escape through the outlet dipped into the water containing jar so as to
condense the fumes to obtain the RAW FUEL floating over the surface as shown in picture above,
Which is further taken out through the outlet provide to the water containing jar.

Fig.15 Initial condition before Condensation.

Fig.16 A layer of oil formed at the top surface after Condensation of the gases.

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Fig. 17
7 litres of Raw fuel collected from about 7.5kg of Plastic.

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6.4. CONVERSION OF RAW FUEL INTO ITS PURE FORM

(DIESEL,Kerosine etc) BY THE PROCESS OF DISTILLATION :

Once the RAW FUEL is obtained it is further subjected to distillation process so as to

obtain the fuel i.e. diesel in its pure form by removing the impurities present in it which can be
then tested into diesel engines for its efficiency.

Fig. 18

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CHAPTER: 07
PHYSICAL PROPERTIES OF DIESEL GRADE OF WASTE PLASTIC
[10]

Sl no. Characteristics Diesel Grade Fuel

1 Flash point in oC 87
2 Fire point oC 92
3 Viscosity @40 oC 3.8
4 Density kg/m3 800
5 Calorific value kj/kg 46988

Fig.20
Test conducted at Mahila University,Vijayapura.

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CHAPTER: 08
PERFORMANCE CHARACTERISTICS [10]

8.1.BRAKE THERMAL EFFICIENCY:

The experimental study on a single cylinder, four-stroke, air cooled DI diesel engine and
air-cooled spark ignition engine with waste plastic oil, At full load, the efficiency is higher for
diesel and petrol fuel. This is due to the fact that at full load, the exhaust gas temperature and the
heat release rate are marginally higher for waste plastic oil compared to diesel.

Graph:1 Brake thermal efficiency

Graph shows that an experimental study on waste plastic oil and diesel fuel blends in
compression ignition engine proved that the thermal efficiency is 27.5% at full load. It is observed
that the engine fuelled WPO60 and WPO80 of diesel grade gives brake thermal efficiency of 24%
and 25.3% respectively at full load. The total heat release for each WPO-DF blends is lesser than
diesel. Hence, the brake thermal efficiency is lower for the WPO-DF blends than diesel.

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8.2.BRAKE SPECIFIC FUEL CONSUMPTION:

Brake specific fuel consumption measures how efficiently an engine is using the fuel
supplied to produce work. It is inversely proportional to thermal efficiency as shown in the graph
below.

Graph:2 Brake specific fuel consumption

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CHAPTER: 09
EMISSION CHARACTERISTICS [10]

9.1. HYDROCARBON EMISSION:

Graph:3 Hydrocarbon emission

Above graph shows that an experimental study on diesel grade fuel of waste plastic oil
shows that, unburned hydrocarbon varies from 36 ppm at low load to 58 ppm at full load, It is
noticed that the concentration of the hydrocarbon of waste plastic oil is little higher than diesel;
the reason behind increased unburned hydrocarbon in waste plastic oil may be due to higher
fumigation rate and non-availability of oxygen relative to diesel.

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9.2. CARBON MONOXIDE EMISSION:

Graph:4 Carbon monoxide emission

Graph shows that, CO2 varies from 2.40% vol. at low load to7.60 % vol. at full load for
different blends,An experimental study on diesel grade fuel of waste plastic oil shows that, CO
varies from 0.08% vol. at low load to 0.10 % vol. at full load for different blends.Here the CO
emission of waste plastic oil is higher than diesel. The reason behind increased CO emission is
incomplete combustion due to reduce in cylinder temperatures.

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CHAPTER: 10
COST ANALYSIS

Reported by: Department of Mechanical Engineering, Faculty of Engineering, Rajamangala

University of Technology Phra Nakhon, Bangkok, Thailand.

1Baht = 1.90 Indian Rupee

16.59Baht = 31.52 Indian Rupee

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CHAPTER: 11
APPLICATION OF PROJECT & FUTURE WORK

1. The obtained fuel could be utilized in diesel generators, vehicles such as tractors and also
passenger vehicles such as cars.
2. The fuel has to be refined at the industrial establishments, based on the results of which small scale industry can
be established.
3. As there is a high demand of crude oil and due to its sky reaching prices , we could take up this

project to setup large or small scale industries and produce the fuel locally at much cheaper rates
directly benefiting the National economy and also a step towards SWAACH BHARAT by
recycling the waste plastic.

4. The application of this project could help in reducing the dependency on the gulf countries and
promote a step towards innovation.

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CHAPTER: 12
RESULTS AND DISCUSSIONS

1. Through our experimentation we concluded that about 600 to 750ml of diesel fuel could be
obtained by burning 1Kg of plastic. Burning 1Kg of plastic in an open environment produces 3Kg
of CO2, whereas by converting it into fuel and burning it reduces 80% of CO2 emissions , which
results in to be quite environmentally friendly.

2. Lesser emission of unburnt HYDROCARBONS in waste plastic pyrolysis oil compared to that of
diesel.
3. The diesel or oil thus obtained has a higher efficiency with around 30 to 40% low production cost
compared to that available in the market.

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CHAPTER: 13
LIMITATIONS

1. High Carbon monoxide emissions compared to that of currently available diesel in the market.
2. High emissions at lesser loads compared to that of higher load working engines.
3. For efficient use of diesel grade fuel of waste plastic, blending it with normal diesel is necessary.

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CHAPTER: 14
CONCLUSION

It is very difficult to find out alternative of plastic. Even plastic´s demand is increasing every day
as well as their waste. This project analysis has observed the use of waste plastics, a factory planning and
its feasibility in Metropolitan City. It is easily assumed that, when the use of waste plastic will increase
then the solid waste management will search more ways to find out to collect them.
The implementation of this project can develop so many opportunities in the city. It can be a
solution to control waste plastic, develop a new technique or idea, and detect the source of diesel for the
country. Bangladesh is such a country where this kind of project could be very promising and effective in
the future

The use of plastic pyrolysis oil in diesel engine in the aspect of technical and economical
is compared and found that oil is able to replace the diesel oil.Though the plastic pyrolysis oil
offers lower engine performance, the plastic waste amount is enormous and it needed to be
process to reduce the environmental problems. Moreover, the engine can be modify follow the
combustion condition of plastic pyrolysis oil. The waste plastic used in the process must be PE or
PP or LDPE in order to protect the contamination of chlorine in the oil.

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11. Sam Haig,et.al Plastic to oil IFM002 final report “Zero Waste Scotland”.

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