CONVERSION OF WASTE PLASTICS TO FUEL

A PROJECT

by

DEEPAK KUMAR.T ( 21906114012 )GANESH.P ( 21906114015 )

HARICHARAN.A.V ( 21906114020 )KARTHIK.R.S ( 21906114029 )

SRI VENKATESWARA COLLEGE OF ENGINEERINGSRIPERUMBUDUR - 602105

May 3, 2023 1

May 3, 2023 2

Under the guidance of

Dr.K.PADMANABHANPROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERINGSVCE

&

Dr.G.DEVASAGAYAM PROFESSOR & HEAD

DEPARTMENT OF APPLIED CHEMISTRY SVCE

CONVERSION OF WASTE PLASTICS TO FUEL

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NEED FOR ENVIRONMENT PROTECTION

Necessity is the mother of all inventions. With improving technology the comfort level of humans have risen tremendously but at the expense of environment. One such example is the POLLUTION.

There are many pollutants that are haunting the face of environment, one such common pollutant is the waste plastics.

Plastics are not only obtained from non-renewable source of energy, but it is generally non-biodegradable. Plastics will be visible for weeks or months and waste will settle in landfill sites for years without degrading.

Plastic wastes block drains, stopping the flow of rain water and sewerage, causing an overflow which becomes the breeding ground for germs and bacteria causing many diseases.

The toxic smoke produced while burning plastics kills thousands each year and people living near a plastic or resin factory are prone to certain kinds of cancer and birth defects.

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NECESSITY FOR AN ALTERNATE SOURCE OF FUEL

• The major environmental concern, according to an IPCC report, is that "Most of the observed

increase in globally averaged temperatures since the mid-20th century is due to the observed increase

in anthropogenic greenhouse gas concentrations" . Since burning fossil fuels is known to increase

greenhouse gas concentrations in the atmosphere, they are a likely contributor to global warming.

• Other concerns which have increased demand revolve around the concept of peak oil, which

predicts rising fuel costs as production rates of petroleum enter a terminal decline. When the

production levels peak, demand for oil will exceed supply and without proper mitigation this gap will

continue to grow as production drops, which could cause a major energy crisis.

• Lastly, the majority of the known petroleum reserves are located in the Middle East. There is

general concern that worldwide fuel shortages could intensify the unrest that exists in the region,

leading to further conflict and war.

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AIM OF THE PROJECT

Our project aims to solve the twin problem of environmental pollution

due to plastics and the need for an alternative fuel. The main aim of our project

is to find a solution to the mounting problem of plastic disposal, for which the

plastics are converted into usable fuel thereby making them environment

friendly.

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LITERARY REVIEW ABOUT PLASTICS

• Oil and Natural gas are the major raw materials used to manufacture plastics.

• The plastics production process begins by heating components of crude oil or natural gas through a process called CRACKING.

• The process results in the conversion of these components into hydrocarbon monomers such as ethylene and propylene. Further processing leads to a wider range of monomers which are chemically bonded into chains called polymers.

• The different combinations of monomers yield plastics with wide range of properties and characteristics.

• Even though the basic makeup of many plastics is carbon and hydrogen, other elements such as Oxygen, Chlorine, Fluorine and Nitrogen are also found in molecular make up of many plastics.

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TYPES OF PLASTICS

PLASTICS

THERMOPLASTICS THERMOSETTING PLASTICS

• Polyethylene terephthalate (PET or PETE)• Polystyrene (Styrofoam)• Polyvinyl Chloride (PVC)• Polytetrafluoroethylene (Teflon)• Polyethylene, LDPE and HDPE• Polypropylene (PP)

• Phenol – Formaldehyde Resin• Urea – Formaldehyde Resin• Melamine – Formaldehyde Resin• Epoxy Resin• Silicone Resin

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PROPERTIES OF PLASTICS

1) They are less brittle than Glass, yet they can be made equally transparent and smooth.

2) They are light weight and at the same time posses good strength and rigidity.

3) They posses good toughness.

4) Their high dielectric strength makes them suitable for electric insulation.

5) They resist corrosion and the action of chemicals.

6) The ease at which they can be mass – produced contributes greatly to the popularity as wrappers

and bags.

7) They posses the property of low moisture absorption.

8) They can be easily molded to desired shapes.

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DESIGN OF APPARATUS

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COMPONENTS IN SETUP

S.NoITEM DESCRIPTION WITH

SPECIFICATIONCAPACITY QUANTITY

1 Three Neck Round Bottom Flask 20 litre 1

2 Single neck flat bottom flask 5 litre 2

3 Catalytic Unit - 1

4 Condenser Unit - 2

5 Conical Flask 2 litre 2

6 Electric Heater 1500 W 1

7 Gear Motor 200 rpm 1

8 Electric Immersion Rod 1000 W 1

9 Structural Fittings - -

10 Plastic Bucket 30 litre 4

11 Hose Pipe - 15 meters

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THREE NECK ROUND BOTTOM FLASK

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SINGLE NECK FLAT BOTTOM FLASK

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CATALYTIC UNIT

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CONDENSER UNIT

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NEUTRALIZING UNIT

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ELECTRIC MOTOR WITH STIRRER

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HEATING MANTLE

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ELECTRIC IMMERSION ROD

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FINAL ASSEMBLY

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CONVERSION OF WASTE PLASTICS TO FUEL

The conversion process includes the following :

• Physical cleaning and Shredding of waste plastics

• Cracking of plastics

• Fractional distillation of crude oil

• Neutralizing the non – condensing gases

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PHYSICAL CLEANING AND SHREDDING OF WASTE PLASTICS

• The plastics such as polyethylene or polypropylene grocery bags, trash bottles, syringe, plastic tumblers, industrial wastes etc. which are considered to be waste products after use are collected and physically cleaned.

• More persistent staining can be removed by washing the object in warm water containing a few drops of non-ionic detergent.

• Severe soiling can be removed with white spirit or isopropyl alcohol, but only where the polymer has been identified as safe for the treatment.

• The plastics which are collected and cleaned are shredded into small pieces to facilitate easy charging of plastics.

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CRACKING OF PLASTICS

• Cracking in general term implies the breaking down of carbon-carbon bonds to

obtain light hydrocarbons from a heavier feedstock.

• The rate of cracking and the end product are strongly dependent on the

temperature and presence of any catalysts.

• Cracking, is a breakdown of a large alkane into smaller,more useful alkanes and

alkene.

• At temperature between 2500C -4000C,the feed hydrocarbon vapors passes

through the catalytic unit where the process of cracking occurs.

• The smaller hydrocarbons passes through the condenser and gets condensed

to liquid.

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CRACKING OF PLASTICS

(CH2=CH-CH3)n 2500C – 4000C MIXTURE OF LIGHTER POLYPROPYLENE Δ FRACTIONS

CATALYST

(CH2=CH2)n 2500C – 4000C MIXTURE OF LIGHTER POLYETHYLENE Δ FRACTIONS

CATALYST

• The condensed liquid is collected in separate delivery flasks depending upon the

boiling point of the liquid as Low boiling point liquid (LBP) and High Boiling point

liquid (HBP).

• The catalytic cracking delivers the wide range of products which can be separated

using the Fractional Distillation process.

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FRACTIONAL DISTILLATION OF CRUDE OIL

Fractional distillation is the separation of a mixture into its component parts,

or fractions, such as in separating chemical compounds by their boiling point by heating

them to a temperature at which several fractions of the compound will evaporate. It is a

special type of simple distillation.

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NEUTRALIZING THE NON – CONDENSING GASES

The outgoing flue gases might contain traces of dioxins and other toxic gases

which leads to air pollution. Hence these gases are passed through chambers of

sodium hydroxide of varying normality. The toxicity in the gases are henceforth

removed and the clean gases are passed to the atmosphere.

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LOADING PLASTICS (PP)

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CLOUD FORMATION

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PASSING OF VAPORS

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REACTION OF CATALYST

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COLLECTION OF CRUDE OIL

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COLLECTION OF LOW BOILING POINT LIQUID

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FORMATION OF WAX

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NEUTRALIZING NON-CONDENSATION GASES

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TESTS CONDUCTED

The following tests were conducted using the fuel obtained.

• Determination of Dynamic Viscosity by Redwood Viscometer

• Flash and Fire Point Test

• Aniline point

• Grease Drop Point Test

• ASTM Distillation Test

• Composition Analysis of crude oil

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Temperature of oil (0C) Viscosity of oil Redwood viscometer ( seconds )

34 34.60

45 33.60

50 33.56

55 33.15

60 31.50

DETERMINATION OF DYNAMIC VISCOSITY BY REDWOOD VISCOMETER

The viscosity test is conducted using Redwood Viscometer and the following results were obtained.

Dynamic Viscosity,µ= 0.0016217 Ns/m2

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ANILINE POINT TEST

The Aniline point of the crude oil is 780C.

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ASTM DISTILLATION POINT

Temperature at which first drop was obtained = 420C

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COMPOSITION ANALYSIS OF CRUDE OIL

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S.No Composition Percentage

1 C 88.19

2 H2 11.80

3 O2 0.01

4 S Not Detected

5 Pb Not Tested

COMPOSITION ANALYSIS OF CRUDE OIL

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S.No Tests Conducted Result

1 Determination of Dynamic Viscosity by Redwood Viscometer

m= 0.00162Ns/ m2

2 Flash and Fire Point Test Flash point = 340cFire point = 380c

3 Aniline point 780c

4 Grease Drop Point Test 520c

5 ASTM Distillation Test Recovery = 92 mL out of 100 mL

6 Composition Analysis of crude oil

C = 88.19 %H2 = 11.80 %O2 = 0.01%

RESULTS OF TEST CONDUCTED

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COST ANALYSIS

TOTAL COST =

COST OF RAW MATERIALS+

COST OF ELECTRICITY+

COST OF DISTILLATION

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COST OF RAW MATERIALS

Waste plastics can be obtained for Rs.3/- per Kg.

To get one litre of crude oil we require 1.23(app.) Kg of waste plastics.

Thus, the cost of plastic is 1.23 x 3 = Rs.3.69

Cost of catalyst required for reaction is Rs.9.50 for 1.23 kg of plastics.

Net Cost = 3.69 + 9.50 = Rs.13.19

( To obtain 1 litre crude oil )

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COST OF ELECTRICITY

PARAMETER ELECTRIC

MANTLE

ELECTRIC

MOTOR

IMMERSION

ROD

Current

(Ampere)

6.5 0.6 4.5

Voltage (Volt) 230 220/230 230

Power (Watt) 1500 138 1000

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The fuel is produced by cracking. The source for heat is an Electric mantle and an

Electric motor is used to stir the charge of plastics. Also an Electric Immersion Rod is used to heat

the water to 700c to pass through the first condenser. From the above data, the total energy consumed during

the trial is the sum of power consumed by Heater ,Immersion rod and Motor .

Thus, Power consumed for 1 hour = 1500 + 138 + 1000

= 2638 Watts

 

Total run time of Experiment (considering Trial 1) = 245 minutes ~ 4.083 hrs

Therefore,2638 x 4.083 = 10652.24 Whr = 10.652 Kwhr.

We know that 1 unit = 1 Kwhr.

Cost of Electricity is Rs.3/- per unit.

Thus cost of production of fuel = 3 x 10.652

= Rs.31.956 (to obtain 4.8 litres of crude

oil)

COST OF ELECTRICITY

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COST OF DISTILLATION

100 ml of crude oil is distilled using ASTM Distillation apparatus. About 45 minutes was required to distill 100 ml of crude oil. The capacity of distillation apparatus is 200Watts per hour.

Thus the electrical consumption to distill 100 ml crude oil = 200 x 0.75 = 150 watts.

Therefore, the electrical consumption to distill 4.8 litres of crude oil = 7200 watts

Thus the cost of electricity = 7.2 x 3 = Rs.21.60 ( for 4.8 liters of crude oil )

Thus the cost of distillation = Rs.21.60

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TOTAL COST OF FUEL

TOTAL COST FOR 4.8 LITRES OF CRUDE OIL = ( 13.9 X 4.8 ) + 31.956 + 21.60

= Rs.120.276

Therefore, cost for obtaining 1 litre of fuel = Rs.21.05

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CONVERSION EFFICIENCY CALCULATION

Conversion efficiency calculation is based on the Law of Reactions i.e. the mass of reactants is

equal to the net mass of the products.Mass of waste plastics = 5.5 kgMass of catalyst = 190 gramsVolume of crude oil extracted = 4.8 liters = 4.8 x 10-3 m3

Density of crude oil =0.855 kg/m3

Mass of crude oil = 4.104 KgMass of Low boiling point fuel = 0.171 KgMass of wax = 0.5 KgTotal mass of reactants = 5.5+(190/1000)=5.69 KgTotal mass of products =4.275 KgMass accounted =4.275 + 0.5 = 4.775 KgConversion Efficiency = (mass of products / mass of reactants) x 100Conversion Efficiency = (4.775/5.69) x 100Conversion Efficiency = 83.92 %

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PERFORMANCE TEST ON KIRLOSKAR ENGINE TEST RIG

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LOAD

IN %

TIME TAKEN

FOR

CONSUMPTI

ON OF 10 cc

FUEL

(SECONDS)

INLET

TEMPERATURE

(0C)

SPEED

(RPM)

VOLTAGE

(VOLTS)

0 70.16 142 1548 230

25 49.65 181 1523 230

50 47.34 262 1490 230

75 35.87 320 1473 230

100 25.47 380 1448 230

Fuel used: B5 Diesel Amount of fuel used : 600 ml

PERFORMANCE TEST

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LOAD IN %FILTER SMOKE

NUMBER

DENSITY OF SMOKE

(mg/m3)

0 0.08 1

25 0.27 4

50 0.74 9

75 1.45 13

100 3.53 81

SMOKE TEST

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COMPARATIVE STUDY OF THE PROPERTIES OF PETROL AND PLASTROL

S.No CHARACTERISTICS 88 octane 93 octane Plastrol

1. Colour Orange Red Straw yellow

2.Density at 150C

Kg/m3710-770 710-770 885

3.

Distillation

Recovery up to 700c10 10 6

Recovery up to 1000C 50 50 10

Recovery up to 1800C 90 90 35

Final boiling point, 0C 215 215 338

Residue, %vol 2 2 11

4. Sulphur, % by mass 0.1 0.1 Not detected

5. Lead content,gm/lit 0.013 0.013 Not tested

6. Octane number 88 93 89.9

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COMPARATIVE STUDY OF THE PROPERTIES OF DIESEL AND PLASTEL

S.NO CHARACTERISTICS STANDARD DIESEL

PLASTEL

1. Flash point, ( 0C ) 38 32

2. Kinematic Viscosity @ 400C 2.0 to 7.5 1.973

3. Distillation percent recovery @ 3500C

90 96.2

4. Density, @ 150C, kg/m3 840 782.5

5. Sulphur, total percent by mass 0.25 NOT DETECTED

6. Smoke point 22 23

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DISCUSSIONS BASED ON RESULTS

From the comparative study of plastrol and petrol based on properties, we can infer the following:

1) The properties of plastrol are similar to that of original petrol. 2) In the case of plastrol the absence of Lead and Sulphur is a good sign for better fuel. 3) Further that the octane number of the fuel ( 89.6 ) is marginally higher than that of the conventional petrol having 88 but lesser than that of the Premium one having 93.This infers that the fuel has better anti-knocking characteristics. 4) The important fact is that petrol comes after nearly 20 years of continuous research but plastrol is relatively new, yet it betters the original petrol in some aspects.

From the comparative study of plastel and Diesel based on properties we can infer the following.

1) The properties of plastel are similar to that of the original diesel. 2) In the case of plastel, the absence of Lead and Sulphur is a good sign for better fuel and hence it reduces the emission drastically. 3) Here again the important fact is that Diesel comes after 20 years of continuous research but plastel is relatively new, yet it betters the original diesel in some aspects.

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VISCOSITY CURVE

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ASTM DISTILLATION CURVE

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EMISSION OF NOX

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EMISSION OF HC

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EMISSION OF CO

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CONCLUSION

• The world’s annual consumption of plastic materials has increased from

around 5 million tonnes in the 1950’s to nearly 100 million tonnes;thus,20 times more

plastic is produced today than 50 years ago.

• Plastic waste recycling is one of the most established recycling activities in

Economically developed countries and Developing countries as well,

as it generates resources and provides jobs.

The recycling of waste plastics also has a great potential for resource conservation

and GHG emissions reduction, such as producing diesel fuel from plastic waste.

• Heavy imports in the field of petroleum can be reduced by converting the

waste plastics to fuel. This increase the economic stability.

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FUTURE SCOPE OF THE PROJECT 

This project is a small step to emphasize that waste plastics can be converted

to fuels. It is a research based project and a lot of studies is yet to be conducted. The

design of the apparatus can be modified to meet the demands of the product.

• The catalyst used in the pyrolysis process can be used along with the plastics instead

of having it as a separate unit.

• A mix of plastics could be used in the process. The cooling water can be circulated

by means of a pump so that the flow rate could be altered depending on the rate of

cooling required.

• The fuel obtained is a crude one. Further refinement is necessary to improve the

properties of the fuel. Long term impacts of the fuel is yet to be ascertained. The non-

condensing gases could be collected and can be tested for any practical usage.

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REFERENCES• Alka Zadgoankar “ Catalytic conversion of waste plastics to Energy ”  • Guruprasad.A.N, Sridhar.S, Lakshmanan.V, Jaikar Sathish.B, “Multidimensional approach for enhancing cleaner environment using plastics” • D.S.Achilias, E.Antonakou, C.Roupakias, P.Megalokonomos, A.Lappas. “Recycling Techniques of Polyolefins from Waste Plastics” • Jain and Jain “Engineering Chemistry”, Dhanpat Rai Publications. • K.Subburayudu, Pyrolysis of Carbonaceous solid wastes as a means of Disposal and Generation of value added fuels and chemicals. • M. S. Mulgaonkar, C. H. Kuo, A. R. Tarrer “Plastics Pyrolysis and Coal Processing with Waste Plastics”  • United Nations Environment Programme “ Converting Waste Plastics into a Resource – Compendium of Technologies” 

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ACKNOWLEDGEMENT We express our thanks to Shri.A.C.MUTHIAH, Chairman, and Dr.R.RAMACHANDRAN, Principal of Sri Venkateswara college of Engineering for their support and encouragement towards our project. We express our profound sense of gratitude to Dr.N.NALLUSAMY, Professor and Head, Department of Mechanical Engineering, Sri Venkateswara college of Engineering, Dr.K.PADMANABHAN,  Professor, Sri Venkateswara college of Engineering and Dr.G.DEVASAGAYAM, Professor and Head, Department of Applied Chemistry, Dr.K.PITCHANDI, Assistant Professor, Sri Venkateswara college of Engineering for their excellent guidance, help, constant encouragement, support and useful suggestions throughout our project work. We take this opportunity to thank Mr.GANGADHARAN of New Venus Industries, Chennai and all Teaching and Non – teaching staff of Department of Mechanical, Automobile, Chemical Engineering and Department of Applied Chemistry of Sri Venkateswara College of Engineering for their co-operation and help during this project work. Last but not least, we thank our parents who have been a source of Inspiration and support for us throughout this project work, standing by us during the difficult times and for providing us with lot of encouragement. We also thank all those who have either directly or indirectly helped us during this project work.

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