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Visvesvaraya Technological University
Visvesvaraya Technological University
Project Report
On
“DESIGN AND FABRICATION OF MACHINE TO CONVERT PLASTIC
INTO OIL AND GASEOUS FUEL PRODUCTION”
(SPONSERED BY KSCST)
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
SUBMITTED BY
Sital Kumar Sah 1NH14ME161
Sandeep Chaudhary 1NH14ME157
Suraj Timilsina 1NH14ME164
Nischal Bhattarai 1NH14ME154
CERTIFICATE
It is certified that the project entitled “Design and fabrication of machine to convert
plastic into oil and gaseous fuel production” is work carried out by Sital Kumar Sah,
Sandeep Chaudhary, Suraj Timilsina, Nischal Bhattarai a bonafide student of New
Horizon College of Engineering, Bangalore in partial fulfilment for the award of degree
of Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya
Technological University, Belgaum during the year 2017-18. It is further certified that
all corrections/suggestions indicated for internal assessment has been incorporated in the
report deposited in the departmental library.The Project Report has been approved as it
satisfies the academic requirements in respect of Project Work prescribed for the said
degree.
1.
2.
ACKNOWLEDGEMENT
“The gratification and euphoria that accompany the successful completion would
be incomplete without the mention of the people who made it possible, whose constant
guidance and encouragement served as a beacon of light and crowned are efforts with
success.”
We are extremely thankful to our internal guide Mr. Lakshmana Naik, Assistant
professor, Mechanical Department, N.H.C.E, for his constant support, encouragement
and valuable guidance throughout the period of the project.
Finally, we thank all the staff of N.H.C.E Mechanical Department and those who
have helped us and contributed directly and indirectly towards the successful completion
of the project work and also our parents for providing unconditional support and
encouragement for caring out the project work.
DECLARATION
We SITAL KUMAR SAH, SANDEEP CHAUDHARY, SURAJ TIMILSINA,
NISCHAL BHATTARAI, student of final semester B.E Mechanical Engineering. New
Horizon College of Engineering, Bengaluru, hereby declare that the dissertation
entitled “DESIGN AND FABRICATION OF MACHINE TO CONVERT PLASTIC
INTO OIL AND GASEOUS FUEL PRODUCTION” has been carried out by my
group and submitted in partial fulfillment of the requirement of the award of B.E in
Mechanical engineering by New Horizon College of Engineering, Bengaluru during
the academic year 2017-2018. Further the matter embodied in the dissertation has not
been submitted previously by anybody for the award of any Degree or Diploma to any
other University.
CERTIFICATE
This is to certify that the above declaration made by the candidates is correct to the best
of my knowledge and belief.
1.2 Disposal methods of waste plastics & their advantages and Disadvantages 9-10
CHAPTER 1
INTRODUCTION
Plastics are one of the most commonly used materials in our daily life and offer
remarkable contribution to the society. They are widely used in packaging and
manufacture of products including electronic, automotive, etc. Plastics are light weight
and can be simply formed. They show non-corrosive behavior. They are reusable and
conserve natural resources. Resultantly, there has been a quick development in plastic
utilization and plastics have been utilized as substitution to wood and metals.
Plastic was invented by Alexander Parkes in 1860 and has high molecular mass.
They are synthetic organic materials produced by polymerization. They may contain other
substances besides polymers to reduce costs and to improve performance. Desired shape
can be given to these polymers by molding or by extrusion Pyrolysis involves the heating
and degradation of the polymeric materials at temperatures between 250°C and 350°C
without oxygen bringing about the arrangement of a carbonized singe (strong deposits)
and an unpredictable division which might be isolated into condensable hydrocarbon oil
and a non-condensable high caloric esteem gas. Scheirs expressed that gases framed amid
the pyrolysis of natural material incorporate carbon monoxide, hydrogen, methane,
carbon dioxide, water, and hydrocarbons, similar to ethane, ethane, propane, propane,
butane, and so forth. The temperature and heating rates can be controlled to produce
desired solid, gas and liquid products because they have considerable influence in the
pyrolysis process. Yin have considered pyrolysis of waste plastic as one of the most
feasible large-scale methods of energy regeneration. This is because waste plastic is a
valuable source of liquid and gas fuels as well as chemicals.
Mainly there are two types of plastics: thermoplastics and thermosetting plastic. If
enough heat is supplied, thermoplastics can be softened and melted repeatedly. On
cooling, they are hardened, so that they can be made into new plastics products. Examples
are polyethylene terephthalate, polystyrene,polyvinyl chloride, high-density polyethylene,
low-density polyethylene, poly propylene etc. They are recyclable. Thermosets or
thermosetting plastics can be melted and shaped only once. It is not good to repeatedly
heat treat such plastics; therefore they remain in solid state after they have been solidified.
Examples are epoxy resin, phenol formaldehyde and urea formaldehyde.
In India alone, the demand for the plastics is about 8 million tons per year. More than
10,000 metric tons per day plastics are produced in India and almost the same amount is
imported by India from other countries. The per capital consumption of plastics in India is
about 3kg when compared to 30kg to 40kg in the developed countries. Most of these
come from packaging and food industries. Most of the plastics are recycled and
sometimes they are not done so due to lack of sufficient market valve of the waste plastics
not recycled about 43% is polyethylene, with most of them in containers and packaging.
PET has become the great choice for plastic packaging for various food products,
mainly beverages such as mineral water, soft drink bottle and fruit juice containers. This
is due to its intrinsic properties that are very suitable for large-capacity, lightweight and
pressure-resistant containers. Different utilizations of PET incorporate electrical
protection, printing sheets, attractive tapes, X-ray and other photographic film [19]. The
extensive applications of PET would cause an accumulation of PET waste in the landfill.
Recycling PET waste was the current practice of handling accumulated plastic waste. In
any case, the massiveness of the holders causes high recurrence of accumulations and
along these lines, builds the vehicle costs. To ease the recycling process, the PET waste
needs to be sorted into different grades and colors that make its recovery inefficient and
uneconomical. Subsequently, other option for PET recuperation, for example, pyrolysis
process has been investigated and the item yield was broke down by a few specialists.
Industrial grade salt) and 43% carbon (derived from hydrocarbon feedstock such as
ethylene from oil or natural gas) [21]. The chlorine property makes PVC an excellent fire
resistance, thus very suitable for electrical insulation. The compatibility PVC to be mixed
With many additives makes it a versatile plastic. Regular applications of PVC include
wire and cable insulation, window frames, boots, food foil, medical devices, blood bags,
automotive interiors, packaging, credit cards, synthetic leather, etc. Even though it has
wide applications, the research done on the PVC pyrolysis found in the literature was
very less due to the dangerous substance that it tend to release when heated at high
temperature.
1.1.4. Low-density polyethylene (LDPE)
As opposed to HDPE, LDPE has all the more stretching that outcomes in weaker
intermolecular power, in this manner bring down elasticity and hardness. Be that as it
may, LDPE has preferable flexibility over HDPE since the side stretching makes the
structure be less crystalline and simple to be shaped. It has a superb protection from
water, along these lines generally connected as plastic sacks, wrapping foils for bundling,
waste packs and significantly more. All these items are commonly used in our daily lives
and therefore, LDPE waste has been accumulated day by day that it is known as the
second largest plastic waste in MSW after PP [20]. As one approach to recoup vitality and
lessen squander, pyrolysis of LDPE to oil item has gotten much consideration by
scientists these days.
1.1.5. Polypropylene (PP)
PP is a saturated polymer with linear hydrocarbon chain that has a good chemical
and heat resistance. Unlike HDPE, PP does not melt at temperature below than 160oC. It
has a lower thickness than HDPE yet has higher hardness and unbending nature that
makes it ideal in plastic industry. PP contributes around 24.3% in plastic squanders class
which are the biggest measure of plastics found in MSW [20]. The diverse applications
include flowerpot, office folders, car bumpers, pails, carpets, furniture, storage boxes and
more. The high demand of PP in daily life causes the amount of PP wastes to increase
each year and therefore, pyrolysis of PP is one of the methods that can be used for energy
recovery. A few analysts have researched the pyrolysis of PP at different parameters to
gauge the fluid oil yield and properties.
1.1.6. Polystyrene (PS)
PS is made of styrene monomers obtained from the liquid petrochemical. The
structure consists of a long hydrocarbon chain with phenyl group attached to every other
carbon atom. PS is naturally colorless but it can be colored by colorants. It is warm
flexibility and it offers sensible sturdiness, quality and delicacy that make this polymer
alluring to be utilized as a part of assortment of areas, for example, in nourishment
bundling, hardware, development, medicinal, apparatuses and toys. The wide range of
applications signifies the large waste amount of PS in MSW accumulated each year.
Unfortunately, PS is excluded in the roadside reusing program in which the reusing
canisters just included glasses, papers, jars, and certain plastics. Even though there is a
plastic category, normally people will not throw the foam food packaging into plastics
recycle bin and they often go to the general bin. In this way, PS is for the most part not
isolated and not financially to gather for reusing because of its low thickness polystyrene
froth. Henceforth, the main way the PS waste can be completely used is through pyrolysis
process in which it can be transformed into more profitable oil item instead of to wind up
in the landfills for eternity.
1.1.7. Mixed plastics
As already said, pyrolysis process has an additional favorable position over the
reusing procedure since it needn't bother with an extreme arranging process. In recycling
process, most plastics are not compatible with each other to be processed together during
recycling. For example, a slight measure of PVC contaminant introduce in PET reuse
stream will debase the entire PET gum by getting to be yellowish and weak that requires
reprocessing [22].This shows that recycling process is very sensitive to contaminants that
it requires all plastics to be sorted based on type of resins, colors and transparency.
However, pyrolysis process seems to be more sustainable since liquid oil still can be
produced from the mixed plastics in the feedstock. This has been encountered by several
researchers who conducted studies of mixed plastics pyrolysis.
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.
On the other hand, Plastics play an important role in day-today life, as in certain
application they have an edge over conventional materials. Indeed, their light weight,
durability, energy efficiency, coupled with a faster rate of production and more design
flexibility, have allowed breakthroughs in fields ranging from non-conventional energy,
to horticulture and irrigation, water-purification systems and even space flight. However
one has to accept that virtues and vices co-exist. Plastics are relatively cheaper and being
easily available has brought about use and throwaway culture. Plastics waste management
has become a problem world over because of their non-degradable property. A majority
of landfills, allotted for plastic waste disposal, are approaching their full capacity. Thus
recycling is becoming increasingly necessary.
In a short span of five years plastics have captured 40% of total 6.79 billion USD
packaging market in India. This situation may grow further in the coming years with
more and more US and European companies entering the market. It would be very
interesting to note the type of litter we generate and the approximate time it takes to
degenerate. Table 1.2 shows the time taken to degenerate for different waste materials.
India has been used as a dumping ground for plastic waste, mostly from
industrialized countries like Canada, Denmark, Germany, UK, Netherlands, Japan, France
and the United States.
Each year more than 100 million tons of plastic are produced worldwide. Though
plastics have opened the way for a plethora of new inventions and devices it has also
ended up clogging the drains and becoming a health hazard. The plastic waste accounts to
about 10 thousand tons per day in India. At these alarming levels of waste generation,
India needs to set up facilities for recycling and disposing the waste.
1. Littered plastics spoils beauty of the city and choke drains and make important
public places dirty.
2. Garbage containing plastics, when burnt may cause air pollution by emitting
polluting gases.
3. Garbage mix with plastics gives problem in landfill operation.
4. Lack of recycling plant to posing unhygienic problem to environment
1.2.3. Side Effect of plastics in nature
1. Durability and chemical structure greatly influences the biodegradability of some
organic compounds therefore an increased number of functional groups (groups of
atoms) attached to the benzene ring in an organic molecule usually hinders microbial
attack.
2. Instead of biodegradation, plastics waste goes through photo-degradation and turns
into plastic dusts which can enter in the food chain and can cause complex health
issues to earth habitants.
3. Plastics are produced from petroleum derivatives and are composed primarily of
hydrocarbons but also contain additives such as antioxidants, colorants, and other
stabilizers.
4. However, when plastic products are used and discarded, these additives are
undesirable from an environmental point of view.
5. Burning of plastics give NOX, COX, SOX, particulate, dioxins, furans and fumes to
increase air pollution with result acid rain and increase global warming.
6. Plastics in land fill area leaching of toxins into ground water.
very different and some plastic articles might contain undesirable substances (e.g.
additives such as flame retardants containing bromine and antimony compounds or
plastics containing nitrogen, halogens, Sulphur or any other hazardous substances) which
pose potential risks to humans and to the environment. The types of plastics and their
composition will condition the conversion process and will determine the pre-treatment
requirements, the combustion temperature for the conversion and therefore the energy
consumption required, the fuel quality output, the flue gas composition (e.g. formation of
hazardous flue gases such as NOx and HCl), the fly ash and bottom ash composition, and
the potential of chemical corrosion of the equipment.
Fig 1.2
The plastic generation and the amount of plastic that
Is subjected to recycling
CHAPTER 2
PROBLEM STATEMENT
The demand for plastic is increasing day by day which possess a tremendous
threat to the environment. Around 5.6 million tons per annum of plastic waste is
generated in India which is about 15,342 tons per day. In the coming few years the waste
amount will still enlarge to an extent, so there should be ways and means to get rid of
these huge amounts and transform it into useful and highly demands applications. Hence,
by pyrolysis process we can convert waste plastics into fuel.
From the previous projects and reports it was found that external heating was
used. As a result, the heat loss was very high leading to low conversion efficiency. In this
project we are using electric heater as source of heat enclosed in a ceramic blanket
insulator which reduced the heat loss and increased the efficiency.
Fig 2.1(a) Gas is used as heating Purpose Fig 2.1(b) Electric heater is used
CHAPTER 3
LITERATURE REVIEW
1. Yasha Shukla, Hemant Singh, Shiwangi Sonkar and Deepak Kumar: - The paper
titled “Design of Viable Machine to Convert Waste Plastic into Mixed Oil for
Domestic Purpose” states in the abstract that the aim of the article is to provide a more
efficient design of machine to convert waste plastic into mixed oil for domestic
purpose. In this machine daily domestic waste like polyethene, polypropylene or
normal plastic carrying bag are converted to oil. This machine employs a closed
container (stainless steel), temperature controlling electric heater and layers of
insulating materials, these materials make machine more efficient and safer for use.
For effective pyrolysis process the temperature of mild steel container (full of waste
plastics) is raised by temperature controlling electric heater and for condensation
process, water at room temperature is employed.[1]
2. Md. Akram Hossain, Md. Raquibul Hasan & Md. Rofiqul Islam: - State in their
paper titled “Design, Fabrication and Performance Study of a Biomass Solid Waste
Pyrolysis System for Alternative Liquid Fuel Production” the abstract is presented
here. Now-a-days production of Bio-fuel is a prime concern in the world due to
decrease other fuel source. The conversion of devdaru seeds into pyrolytic oil by fixed
bed reactor has been taken into consideration in this study. A fixed bed pyrolysis
system has been designed and fabricated for obtaining liquid fuel from biomass solid
wastes. The major components of the system are: fixed bed reactor, liquid condenser
and liquid collectors. The devdaru seeds in particle form is pyrolized in an externally
heated 7.6 cm diameter and 46 cm high fixed bed reactor with nitrogen as the carrier
gas. The reactor is heated by means of a cylindrical biomass source heater. Rice husk,
cow dung and charcoal are used as the energy source. The products are oil, char and
gas. The parameters varied are reactor bed temperature, running time and feed particle
size. The parameters are found to influence the product yields significantly. The
maximum liquid yield is 51 wt.% at 500o C for a feed size of 1.18 mm at a gas flow
rate of 5 liter/min with a running time of 90 minute. The pyrolysis oil obtained at
these optimum process conditions are analyzed for some of their properties as an
alternative fuel. We get the higher heating value of devdaru seeds oil is 24.22 MJ/kg.
The heating value of the oil is moderate.[3]
4. S.L. Low, M.A. Connor and G.H. Covey: - The paper titled “Turning mixed plastic
wastes into a useable liquid fuel”, the abstract is presented here. As landfill and
incineration become more expensive and less accepted, the recycling of plastic wastes
is gaining increasing importance. More emphasis is thus being given to new disposal
options, which have high energy recovery values and are more environmentally
attractive. Pyrolysis is one promising method for the treatment of mixed and
contaminated plastic wastes. Plastics are thermally degraded to produce useful liquid
hydrocarbons, which can then either be added to existing fuel or solvent product, or
returned to a refinery where they can be added to the feedstocks. A simple pyrolysis
reactor system is described. Results of pyrolysis tests showed that pure samples of
polyolefinic and polystyrene resin can readily be pyrolysed to produce liquid yields in
excess of 70%. However, liquid yields were affected by heating rates and heat loss
patterns in the reactor system. Further experimental work suggests that when
pyrolysed, mixed plastic wastes behave much like the resins from which they
originate. In light of the results from the experiments, the technical feasibility of
setting up a pyrolysis plant in Victoria to process waste plastics into liquid fuel was
discussed. This study thus forms the ground work needed for the design of a small
pyrolysis plant.[18]
5. Achyut K. Panda, R.K. Singh, D.K. Mishra (et al):- “Thermolysis of waste
plastics to liquid fuel”. In this research projects he used wide range of old and
new technologies for chemical recycling of waste plastic to liquid fuel. [6]
6. Tiwari D.C., Ejaz Ahmad, Kumar Singh K.K 2009(et al):- wrote on catalytic
cracking process in which waste plastic is melted and cracked in the absence of
oxygen and at very high temperature, the resulting gases were cooled by condensation
and resulting crude oil was recovered. From this crude oil various products petrol,
diesel and kerosene etc. can be obtained by distillation. [7]
7. Antony Raja and Advaith Murali (et al):- “Conversion of Plastic Wastes into
Fuels”.He concluded that we can convert all types of waste plastic into hydrocarbon
fuel at the temperature profile 350ºC to 500ºC through pyrolysis process. [8]
8. Wenger Jorn.Investigated (et al):- The pyrolysis of waste plastics (HDPE and
polypropylene) in a tubular reactor at 500 °C temperature in the presence and absence
of Y-zeolite catalyst. It was found that the yields of gases, gasoline and light oil could
be increased in the presence of catalyst. [9]
9. Manish Chand Sharma, Neelesh Soni (et al):- Issued a paper in 2013 on
“Production of alternative fuel from waste oil and comparison with fresh diesel”. This
research paper compares the diesel obtained from pyrolysis of plastic oil with
conventional diesel oil. [10]
10. C. Wongkhorsub, N. Chindaprasert (et al):- Published a paper in July 2013 titled
“A Comparison of the Use of Pyrolysis Oils in Diesel Engine”. This research
describes a comparison of the use of pyrolysis oils which are the plastic pyrolysis oil
and diesel oil in the assessment of engine performance, and feasibility analysis.
Pyrolysis oils and waste plastic are studied to apply with one cylinder multipurpose
agriculture diesel engine. Thus, a comparison between the two is studied. [11]
11. Alkazadagaonkar (et al):- The experiments on conversion waste plastic into liquid
fuels using new technology. We can convert all types of waste plastics into liquid
fuels at a temperature of 3500C-500oC.
12. 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.
14. A.G. Buekens, H. Huang (et al.):- Catalytic plastics cracking for recovery of
gasoline-range Hydrocarbon liquid fuels municipal plastic wastes, Resources,
Conservations and Recycling.1998
15. F murphy:- 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
17. A.Lopez (et al):-Pyrolysis of munciple plastic wastes. Influence of raw material
composition under catalytic conditions. Waste management journal home page.
18. Bockhorn H (et al.):-Kinetic study on the thermal degradation or thermal pyrolysis
of plastic wastes. They concluded that, the temperature and reaction time thermal
pyrolysis is slightly greater than the catalytic pyrolysis. [8]
Addition of catalyst enhances the conversion and fuel quality. There is a significant
reduction in the degradation temperature and reaction time under catalytic condition.
Fuel obtained from pyrolysis process shows nearly same properties as that of diesel
fuel and petrol fuel oil. So we can use plastic oil as alternative fuel.
CHAPTER 4
OBJECTIVES
To build up the reason for the improvement and execution of waste plastics
reusing with the use of environmentally sound technologies (EST). To advance
asset protection and ozone depleting substances
To raise awareness in developing countries on plastic waste and its possible reuse
for conversion into diesel or fuel.
To reduce the dependency on gulf countries for fossil fuels, thereby contributing
to the economic growth of the country.
To collect the household plastic waste from different places.
To develop and fabricate the pyrolysis unit to produce liquid fuel from plastic
waste.
Conversion of household plastic waste in to liquid fuel.
To purify the produced liquid fuel by water washing method.
To conduct the different experiments to determine the different properties of
liquid fuel.
Compare the properties of liquid fuel with diesel fuel.
CHAPTER 5
METHODOLOGY
5.1. PYROLYSIS PROCESS
Pyrolysis is the thermal decomposition of materials at higher temperatures in the
absence of oxygen (or an inert atmosphere).It is a chemical reaction process which
involves molecular breakdown of larger molecules into smaller molecules in the presence
of heat. It includes the difference in concoction arrangement and the procedure is
irreversible. The word pyrolysis is begat from the Greek-determined components pyro
which signifies "fire" and lysis which signifies "isolating".
Pyrolysis process finds a heavy application in the chemical industry as well. For instance,
it is utilized to deliver ethylene, numerous types of carbon, and different chemicals from
oil, coal, to create coke from coal.. Aspirational applications of pyrolysis would be to
convert waste plastics back into usable oil, or waste into safely disposable substances.
Pyrolysis varies from other high temperature forms like ignition and hydrolysis .It as a
rule does not include the expansion of different reagents, for example, oxygen (O2, in
burning) or water (in hydrolysis).However, in practice, it is often not practical to achieve
a completely oxygen or water-free conditions, because some amount of oxygen is always
present which cause oxidation.
Various technologies and methodologies can be used for the pyrolysis process
such as batch reactor, semi batch reactor, fluidised bed reactor, fixed bed reactor etc. The
process can be performed with or without the use of catalyst. The different types of
catalyst that can be used for plastic pyrolysis are zeolite, alumina (Al2O3), silica (SiO2),
etc.
Distillation Liquid
Condensing
collection
Testing
The plastic waste is collected from different sources such as household, hotels,
market etc. and separated on the basis of their types. The various types of waste plastic
include food containers, milk covers, water bottles, packaging foams, disposable cups and
plates, broken plastic chair, shopping bags etc. The plastics can be separated as PET,
HDPE, LDPE, polypropylene, etc. After the separation, plastic is cleaned to remove any
impurities like dust, dirt, with the help of soap water. The plastic is then dried in the sun
to remove the moisture present and cut into small pieces of size less than 5cm.
5.3.3. HEATING
An electric heater which has capacity of 3KW is used to heat the reactor. A
Nichrome coil is used as heating element and power supply is 230V, 50Hz AC. A
temperature indicator and controller are used to record and maintain the required
temperature. The heater can increase the temperature up to 200°C within 15 minutes and
the temperature indicator and controller can record temperature up to maximum of
1200°C.
5.3.4. CONDENSING
The plastic waste gets evaporated at temperature 250-350°C. This vapour is condensed to
atmospheric temperature by using tube condenser.
5.3.6. DISTILLATION
Once the fuel is collected, the oil is distilled to increase purity. For this, a sample
of oil (about 250ml) is taken in a round bottom flask and heated to about 70°C. The oil
starts to boil and the vapour is condensed and collected in a separate flask. Water is
supplied for condensing the process. Thus, fuel with better property is achieved.
5.3.7. TESTING
The oil sample is finally taken to laboratories for testing its properties like density,
calorific value, flash point, fire point, viscosity, etc. The test is carried out for different
samples before coming to final result.
CHAPTER 6
EXPERIMENTAL SETUP
6.1 Introduction
All the experimental setup and instruments used in this process will be discussed
in this section. The procedure followed to convert plastic into oil. All the setup are
mentioned in the order of one after another.
Water
Reactor
@250oC
Condenser Separator
-3500C
Waste
Plastic
pieces
Liquide Fuel
Residue
Plastic was cut into a number of small pieces. The plastic chips were washed,
dried, and fed into a pyrolysis reactor unit. The pyrolysis reactor used in this process was
in cylindrical chamber. The reactor was placed inside the electric heater. The heater has a
capacity of 3Kw which is insulated by glass wool. By means of high temperature outside
the reactor vacuum was crated inside of reactor. Inside the heater there is a sensor which
is connected whit temperature controller which control the temperature outside the
reactor. The process was carried out between the temperature ranges of 250oC-350oC
outside of reactor for 1 hours and 30 minutes. The products of pyrolysis is in the form of
vapour were send to a water cooled condenser and the condensed liquid was collected as
a fuel. The figure 6.2 shows the Experimental setup of the process. Fuel collected was in
crude form.
6.3.1. Reactor
Inner diameter-137mm
Height- 420mm
Thickness-3mm
Reactor is made of mild steel material with flange at the top end. Asbestos gasket
is provided in between of flange to make leak proof. Reactor and flange has a same size
hole where bolt and nut is fitted to close the reactor chamber. Reactor is kept inside of
heater. Reactor is heated externally by means of high temperature inside of heater. The
pyrolysis is simple process in which plastic is melted at high temperature about 250oC-
350oC in the absence of oxygen. Due to thermal cracking of plastic substance is obtained
and finally the end products will form in the form of oil.
Material-Plastic
No. of tap-2
Condenser is made up of plastic material with 2 taps to remove water and oil from
the tank. After heating the plastic in the reactor the gas is allowed to escape through the
outlet. Condenser pipe is dipped into the water containing jar so as to condense the
vapour to collect the fuel drop by drop from outlet of the condense tank.
6.3.4. Heater
Power- 3Kw
Size-150*150mm
Height-300mm
Heater is used to heat the reactor for pyrolysis process. Heater coil is made up of
Nichrome wire (Ni-80%, Cr-20%) which has the power capacity of 3Kw. It requires
230V input supply. Heater is insulated with glass wool to reduce the heat loses from the
heater. Heater is connected with the temperature controller. Which control the
temperature of the heater. Sensor is used to sense the temperature of the heater which is
connected to controller.
Controller is the device which is used to control the temperature of the heater and
also supply the power to the heater. It has the capacity to control the temperature up to
10000C. The regular working temperature range is 250oC-350oC. MCB is used in
controller for safety purpose. If there is any short-circuit or over load then the MCB will
full down. Due to which power circuit will break and there is not any power supply
toward the heater.
6.3.6. Sensor
Sensor is the device which is used to sense the temperature of the heater. This is K
type thermocouple. Its one end is kept into the heater and other end is connected to the
controller. It can sense the temperatures up to 800oC.
The plastic fuel so obtained is further distilled to improve the purity of the fuel.
The experimental setup is as shown in the above figure 6.9. About 250ml of fuel is
poured in a round bottom flask and mounted on a heater. The temperature of heater is
maintained at around 70 degree Celsius with the help of thermostat. Water in and water
out is provided for condensation. Once the fuel starts to boil, the evaporated vapour is
passed through condenser and collected in a flask in a pure form with improved
properties.
CHAPTER 7
PROPERTIES OF FUEL
Density: It is defined as mass per unit volume. It is given as
Mass
Density =
Volume
Calorific value: Calorific value is defined as the amount of energy released by the
complete combustion of a material or fuel in the presence of oxygen. Its Si unit is kJ/kg or
kcal/kg. It is given by formula
heat generated
Calorific value = mass flow rate
Viscosity: It is defined as the resistance offered by the fluid for the flow of fluid over
another layer when they are in motion relative to each other.
Flash point: It is the minimum temperature at which fuel produces sufficient vapour to
produce a flash when a flame is brought near it.
Fire point: It is the minimum temperature at which fuel produces sufficient vapour such
that it continues to burn at least for 5 seconds when a flame is brought near it.
CHAPTER 8
Fire point: - After recorded the flash point continuous give the external fire until the fire
point obtained. Once the fire point obtained the temperature is recorded. At 32oC
temperature the fire point is obtained.
Weight of oil
Density of oil (ρ) =
volume of oil
38×1000
=
50
= 760 Kg/m3
4. Place the ball to close the valve at the bottom of the viscometer.
5. Pour the oil to be tasted.
6. Place the flask at the bottom of the viscometer.
7. Insert the thermometer on the top to take the temperature.
8. Heat the water filled in the bath.
9. Lift the ball to flow the oil
10. Stop the stop watch when the oil reaches the 50 ml mark on the flask.
11. Record the time taken for 50ml of oil flow into the flask.
12. Calculate the viscosity of the fuel.
188
(γ) = (0.26 × 𝑡 − ) × 10−6
𝑡
188
γ= (0.26 × 31 − ) × 10−6
31
Calorific value: - Calorific value of fuel is the quantity of heat produced by its
combustion at constant pressure and under normal condition. The calorific value of
plastic pyrolysis is 47532.740326 kJ/kg
CHAPTER 9
CHAPTER 10
Table 10.1
CHAPTER 11
11.1 Advantage
1. The waste plastic is converted in fuels having high calorific value.
3. Burning of plastic produces toxic gases like nitrogen dioxide, sulphur oxides,
dioxins and other harmful gases. Plastic pyrolysis process produces minimum
hazardous gases. Hence, the process helps to control environmental pollution.
5. It promotes environmental protection. When people realise that waste plastic can
be converted into fuel they won’t dump plastic unnecessarily.
6. Plastic fuel can act as an alternate fuel to diesel, petrol, kerosene, etc.
7. Plastic fuel can be used as good source of heat in sugar industry, brick industry,
and steel industry.
9. The plastic fuel can help in reducing the dependency on gulf countries for
petroleum.
11.2 LIMITATIONS
CHAPTER 12
5. The application of this project could help in reducing the dependency on the gulf
countries and promote a step towards innovation.
CHAPTER 13
CONCLUSION
Plastic bears a major threat to the current scenario and the environment. Millions of
tonnes of plastics are produced on the daily basis and only few percentage of the waste
plastic are being successfully recycled. Since, plastic takes long years to decompose,
some alternative to plastic should be developed. Also, the world is facing the problem of
shortage of petroleum.
Therefore, conversion of waste plastic into fuel can provide a better solution to the
disposal problem of waste plastic as well as act as an alternative to fossil fuel. From the
experiments and trials, we also found that by using pyrolysis method we were able to get
recover 80-85% oil for polypropylene plastic (Type-5). However, the output varies
depending on the type of plastic used. Also, the plastic fuel showed properties similar to
that of diesel fuel.
Hence, we can conclude that pyrolysis of plastic into fuel can solve both the
problem of plastic waste management as well as shortage of fossil fuel if plant is set up at
the commercial level.
BILL OF MATERIAL
Description Quantity Rate Amount
Rs.
Temperature 1 5200 5200
indicator and
controller
Ceramic Blanket 2 Roll 1575 per roll 3150
Heater coil 1 3300 3300
(3Kw)
Sensor 1 750 750
R B Flask 1 342 342
L BEND tube 1 206 206
Wire 20m 19 per meter 380
Power board 1 120 120
Switch 1 40 40
Tape 1 25 25
Plug 1 60 60
Reactor with 1 3000 3000
flange
Condensing pipe 1 250 250
(full set)
Total 16,823
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