CHAPTER 1
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.
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.
Every year
humans produce nearly 280 million tons of plastic, and much of that plastic
ends up in theenvironment, harming marine life and other ecosystems. The
chemical bonds that makes plastic sodurable makes it equally resistant to
natural processesof degradation. Since plastics are non-biodegradable in
nature, it is very difficult to eliminate the waste plasticsfrom nature. Since
1950s 1 billion tons of plastic have been discarded and may persist for
hundreds or even thousands of years. Expenditure incurred on disposal of
plastic waste throughout the world is around US$ 2 billion every year. Even for
a small country like Honk Kong spends about US$ 14 million a year on the exercise
. The majority of the plastic waste ends up in landfills, and becomes a carbon
sink where it may take up to 1000 years to decompose and potentially leak
pollutants into the soil and water.
Also the
plastic wastes are dumped in the oceans threatening the health and safety of
marine life. The uncontrolled incineration of plastic produces polychlorinated
dibenzo-p-dioxins, a carcinogen. So,converting the waste plastic into crude oil
will have two benefits. First of all, the hazards caused due to plastic
waste can be reduced and
secondly, we will be able to obtain some amount of oil from it, which can be
further purified to be used as a fuel in different areas such as
domestic fuel, fuel for
automobiles and industries etc.Thereby, our dependency on fossil fuels will
reduce to acertain extent.
CHAPTER 2
LITERATURE REVIEW
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.
CHAPTER
3
METHODLOGY
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.
CHAPTER 4
SELECTION
OF MATERIALS
4.1
CLOSED CHAMBER
Fig4.1 closed chamber
Closed
chamber is made up of mild steel. It can withstand heating temperature upto
1320 ⃰⃰C. Waste plastics like polyethylene, polyethylene terepthalate, pvc,
polystyrene, are inserted into the closed chamber and allow to heat at a
required temperature. It consists of pressure gauge which is used to measure
the pressure of heating.
The
melting point of mild steel, or
low carbon steel, is
usually 2,600 degrees Fahrenheit, or 1,427 degrees Celsius. Mild steel is one of the most
commonly used types of industrial steel,
and it consists of an alloy ofsteel and carbon
MECHANICAL
PROPERTIES:
Yield
strength 370mpa
Tensile
strength 370mpa
Elongation
at break 15.0%
Modulus
of elasticity 205gpa
Reduction
of area 40.0%
4.2 CONDENSER
Fig4.2 condenser
Condenser is a device or unit used to condense a substance from its gaseous to its liquid state, by cooling it. In so doing, the latent heat is given up by the substance, and will transfer to the
condenser coolant.
Condensers
can be made according to numerous designs, and come in many sizes ranging from
rather small (hand-held) to very large (industrial-scale units used in plant
processes).
For
example, a refrigerator uses a condenser to
get rid of heat extracted from the interior of the unit to the outside
air. Condensers are used in air
conditioning, industrial chemical processes such as distillation, steam power
plants and other heat-exchange systems. Use of cooling water or
surrounding air as the coolant is common in many condensers
4.3 PIPES
Fig4.3 coupling
Cast iron pipe is a pipe which has had historic use as a
pressure pipe for transmission of water, gas and sewage.. It comprises
predominantly a gray cast iron tube and was frequently used uncoated,
although later coatings and linings reduced corrosion and improve hydraulics.
Cast iron pipe was superseded by ductile
iron pipe, which is a direct development, with most existing manufacturing
plants transitioning to the new material during the 1970s and 1980s. Little
cast iron pipe is currently manufactured.
Cast
iron pipe is used to carry the hot gases of burnt plastics and sent to the
condenser coil. The coil cool the hot
gases and sent to further process.
Cast
iron proved to be a beneficial material for the manufacture of water pipes and
was used as a replacement for the original elm pipelines laid in the ground
earlier. These water pipelines were composed of individually cast pipe
sections, often termed sticks, jointed together by a bell and spigot joint.[1] Here one end of the pipe stick is flared,
termed the bell or socket, to enable the opposite end of the next stick, the
spigot end, to be inserted to create a joint. The gaps in these joints were
sealed with oakum to
prevents the water leaking out. A molten-lead joint was then run around the
socket to ensure that the oakum seal remained in place.
Fig4.4 pipe lines
4.4 CONDENSER FAN
Fig4.5 condenser fan
·
Air cooled – If the condenser is located on the
outside of the unit, the air cooled condenser can provide the easiest
arrangement. These types of condensers eject heat to the outdoors and are
simple to install.
·
Most common uses for this condenser are domestic refrigerators,
upright freezers and in residential packaged air conditioning units. A great
feature of the air cooled condenser is they are very easy to clean. Since dirt
can cause serious issues with the condensers performance, it is highly
recommended that these be kept clear of dirt
·
Larger condensers are also used in industrial-scale distillation
processes to cool distilled vapor into liquid distillate. Commonly,
the coolant flows through the tube side and distilled vapor through the shell
side with distillate collecting at or flowing out the bottom.
·
In this type of condenser, vapors are
poured into the liquid directly. The vapors lose their latent heat of vaporization; hence, vapors transfer their heat into
liquid and the liquid becomes hot. In this type of condensation, the vapor and
liquid are of same type of substance. In another type of direct contact
condenser, cold water is sprayed into the vapor
to be condensed.
4.5 FAN
MOTOR
fig4.6 fan motor
These commercial-duty motors feature
high starting torque, cool running temperature, and a reversing plug. All
models are suitable for outdoor air conditioner condensers and refrigeration condensers.
Insulated
and engineered for trouble-free operation, these high-ambient condenser fan
motors help to handle full-rated loads at high temperatures. Each motor
features a corrosion-resistant coating on its rotor core to help extend long
motor life. The motors also feature easy-to-remove drain plugs in each end
shield. Use with outdoor air conditioning and refrigeration condensing units
and heat pumps.
Motor type AC- Motor
Speed 1075
rpm
Voltage 208-230
v
CHAPTER
5
5.1
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 figure demonstrates where the atomic composition in most plastics is
similar to those in gasoline and diesel derived from crude oil.
CHAPTER 6
COLLECTION & IDENTIFICATION OF WASTE PLASTIC
Fig6.1 plasitic waste
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.
Fig6.2
grinded plastic
Ø 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 Properl.
Fig6.3
pyrolysis process
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
CHAPTER 7
PLASTIC OIL
7.1 LEVEL OF PLASTIC OIL PROCESS IN THAT PROCESS
Fig7.1
level of plastic oil
Linear low-density polyethylene (LLDPE) LLDPE is defined by a density range of
0.915–0.925 g/cm3. LLDPE is a substantially linear polymer with significant
numbers of short branches, commonly made by copolymerization of ethylene with
short-chain alpha-olefins (for example, 1-butene, 1-hexene, and
1-octene).
7.2 PLASTIC OIL
fig7.2
plastic oil
pyrolysis of waste plastic and
tires. Industry that converts waste plastic and tire into pyrolysis products
like pyrolysis oil, pyrolysis gas,
carbon black is called pyrolysis plant. Pyrolysis plant offers
new business opportunities like: Recycling. Waste to energy.
Pyrolysis is a thermochemical
decomposition of organic material at elevated temperatures in the absence of
oxygen (or any halogen). It involves the simultaneous change of chemical
composition and physical phase, and is irreversible. The word is coined from
the Greek-derived elements pyro "fire" and lysis
"separating".
CHAPTER 8
WHY WE ADOPT PYROLYSIS
PROCESS
Comparison of Green House Gas (GHG) Emissions by Pyrolysis process with
other processes:
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.
PHYSICAL
PROPERTIES OF DIESEL GRADE OF WASTE PLASTIC
S.NO
|
CHARACTERISTICES
|
DIESEL GRADE FULE
|
1
|
Flash point in °C
|
87
|
2
|
Fire point °C
|
92
|
3
|
Viscosity@40 °C
|
3.8
|
4
|
Density kg/m3
|
800
|
5
|
Calorific value KJ/Kg
|
46988
|
CALORIFIC VALUES OF PLASTICS
Fuel
|
Calorific value (MJ/kg)
|
Methane
|
53
|
Gasoline
|
44
|
Fuel oil
|
43
|
Coal
|
33
|
Polyethylene
|
43
|
Mixed plastics
|
30-40
|
CHAPTER 9
DESIGNING OPERATION
9.1 SOLID WORKS DESIGN OF COVER PLATE
Fig9.1 cover plate
9.2 SOLID WORKS DESIGN OF CYLINDER
Fig9.2 cylinder
9.3 SOLID WORKS DESIGN OF CONDENCER
Fig9.3 condenser
9.4 SOLID WORKS DESIGN OF ASSEMBLY PART
Fig9.4 assembly part
9.5 HEAT ANALYSIS FOR COVER PLATE
Fig9.5 heat analysis for cover plate
Cover plate is the top cap of the chamber. It
has a hole at the top of the cap. The hole which is present at the top is used
to pass the hot gases coming out from the chamber. Various colour indicates
that heat analysis for the cover plate.
9.6 HEAT ANALYSIS FOR
CYLINDER
Fig9.6 heat analysis for cylinder
This is a closed chamber. In this chamber
various colour denotes that heat analysis of the chamber. Red colour shows that
heat analysis process is high when compare to all other colours and blue colour
shows that chamber having very low heat analysis. In between colour shows that
chamber having moderate heat analysis. By using solid works software chamber heat
analysis process is shown.
CHAPTER 10
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. V.
CHAPTER 11
RESULTS
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.
CHAPTER 12
CONCLUSION
·
From this project we can reduce the plastics which
are present in our environment.
·
We can also use the oil for our automobile purpose
·
We can also control the pollution
·
We can use this as alternate fuel also
CHAPTER 13
REFERENCES
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& Technology 2( 5): 29-31
2)Daniel D. Chiras (2004) : Creating a Sustainable
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