CFSC Manjeri, Industries Dept., Govt.

of Kerala

Plastic Waste Pyrolysis

PROFILE ON

THE SETTING UP OF PYROLYSIS PLANT FOR PLASTIC WASTES CONVERSION INTO INDUSTRIAL DIESEL (PYROLYSIS OIL), GASEOUS FUEL & CARBON BLACK

Prepared By: Dr. T. Muraleedharan Nair

Common Facility Service Centre, Manjeri

CFSC Manjeri, Industries Dept., Govt. of Kerala

Plastic Waste Pyrolysis

PLASTIC WASTE PYROLYSIS

INTRODUCTION

Environmental pollution due to plastic wastes is a global phenomenon today. Recycling waste plastics into reusable plastic products is a conventional strategy followed to address this issue for years. However this technique has not given impressive results as cleaning and segregation of waste plastics was found difficult but indispensible in this technique. It is estimated that approximately 10 thousand tons of plastics waste per day is generated in our country. Plastic wastes include different types viz. Low Density Poly Ethylene (LDPE), High Density Poly Ethylene (HDPE), Poly Ethylene Terephthalate (PET), Polypropylene (PP), Polystyrene (PS), Poly Vinyl Chloride (PVC) etc. As the plastic waste segregation is difficult it was essential to have novel technologies for plastic waste disposal. Today, sophisticated technologies are available for plastic waste management. Pyrolysis is one such technique used not only for waste disposal but to produce useful products like industrial diesel, gaseous fuel, carbon black etc. This project discusses the pyrolysis of waste plastics into useful gaseous and liquid fuels along with carbon black.
PYROLYSIS

Pyrolysis is the thermal degradation of waste in an oxygen-starved environment in which the oxygen content is low for gasification to take place. Pyrolysis liquefaction is a non-combustion heat treatment that catalytically (chemically) decomposes waste material by applying heat, directly or indirectly to the waste material in an oxygen free environment. It is an endothermic reaction which requires an input of energy that is typically applied indirectly through the walls of the reactor in which the waste material is fed into. Pyrolysis liquefaction occurs under pressure and at operating temperatures above 430oC. Industrial Oil (Pyrolysis oil), Charcoal and Syn-gases are produced.

CFSC Manjeri, Industries Dept., Govt. of Kerala

Plastic Waste Pyrolysis

CONVERSION EFFICIENCY

The output of a plant with input capacity of 10,000 Kgs mixed plastic wastes/day is as follows; Pyrolysis Oil (Diesel: 85%, Kerosene: 7% & Petrol: 8%): 6500 to 9000 lit Hydrocarbon Gas: 500 to 1000 Kg Carbon Black: 500 to 700 Kg
WASTES RECOMMNDED

Waste plastic, Electronic scrap, Mixed Plastic (LDPE, LLDPE, HDPE, PP, Nylon, Teflon, PS, ABS, FRP), Multilayered Plastic, Waste tyres, Rubber
WASTES NOT RECOMMENDED

Agricultural waste
MARKET AND SCOPE

The successful implementation of this project depends on the regular supply of plastic wastes. As the plastic waste generation is alarmingly increasing every day there will not be any scarcity for this material. There is tremendous scope for the products of pyrolysis like Industrial Diesel (Pyrolysis Oil), Gaseous Fuel and Carbon black. The important applications are; * Pyrolysis oil (Industrial Diesel): Used in Electric Generators, Boilers, Diesel Pumps, Furnace, Hot air generators, Hot water generators, Thermic fluid heater, etc. * Hydrocarbon Gas: Reused in the Plant * Carbon Black: Used in Rubber Industry, Plastic Industry, Paints, Inks etc.

CFSC Manjeri, Industries Dept., Govt. of Kerala

Plastic Waste Pyrolysis

PROJECT PARAMETERS

i) Production Capacity/Annum Proposed: Conversion of 31,20,000 Kg of plastic wastes into 21,84,000 lit Industrial Oil, 1,56,000 Kg Carbon Black and 1,56,000 Kg Hydrocarbon Gas ii) Land required: Minimum 40-50 cents of land is required iii) Location: Industries Land at Thiruvanathapuram, Ernakulam and Kozhikode iv) Raw Material and other Utilities: Raw material includes waste mixed plastic scrap of various kinds like LDPE, LLDPE, HDPE, PP, PS, Electronic scrap, Multi layered Plastic etc. Depolymerization Catalyst and special additives are required. Water requirement is about 2 KL/day and connected load is estimated at 50 KVA. V) Plant and Machinery: The following machinery is essentially required; Machines Machinery Include: Bucket Elevator with hopper and duct, Raw Material Feeder, Pyrolysis Reactor System, Heating System, Condensers, Receivers for Pyrolysis Oil, Hydrocarbon Gas Collection System, Exhaust pipe, Suction blowers, Cooling tower, Scrubbing system, Charcoal recycler, Charcoal Filter, Charcoal pulverizer, Fittings and Fixtures etc. Total Cost : 2,19,00,000/-

CFSC Manjeri, Industries Dept., Govt. of Kerala

Plastic Waste Pyrolysis

vi) Man Power: Man power requirement is estimated as 18 which include 10 semi-skilled workers, 3 Managers, 1 Maintenance Engineer, 2 Office Assistants and 2 Watch men vi) Project Cost: Total project cost is estimated at Rs. 3,09,71,200/- lakhs Item Fixed Capital: Land (IE) & Building Machine Furniture Preliminary Pre-operative Expense Taxes, licensing expenses, transportation, installation etc Sub Total Working Capital Personnel/2month Raw Material/2month Utilities/2month Contingencies, technical know-how, Pre-operating expense etc./2 month Sub Total Total Capital Investment 4,57,600 41,96,400 4,25,200 1,42,000 52,21,200 _________ 3,09,71,200 14,50,000 2,19,00000 50,000 1,50,000 22,00000 2,57,50,000 Cost (Rs.)

CFSC Manjeri, Industries Dept., Govt. of Kerala

Plastic Waste Pyrolysis

vii) Means of Finance: Self Loan from banks/FIs Total viii) Sales Turnover Sales turnover/year is estimated to be Rs. 7,70,64,000 FINANCIAL INDICATORS Net profit/year: 3,88,92,332 Breakeven point: 17.05 % Investment Payback Period: 0.80 years Net Profit Ratio: 50.47 % Rate of Return on Investment: 125.58 % CONCLUSION The project is technologically and economically viable. There is no scarcity for plastic wastes as the plastic waste generation has already become a habit of our society. In Trivandrum city alone the plastic waste generated per day is estimated as 28 tons. The end products like Industrial oil, Carbon black and Gaseous fuel manufactured from plastic wastes invites customers as these products are extensively used for various applications and the cost of these items are lower compared to the same products produced from petroleum sources. Hence this project is viable and recommended for implementation. ______________________________________________________________
If any queries on this project please feel free to contact, Common Facility Service Centre (Department of Industries & Commerce, Govt. of Kerala), Payyanad, Manjeri. Contact Nos: 0483-2768507/09495500526/09388479254

100,00000 2,09,71,200 3,09,71,200