MINI PROJECT SEPTEMBER

2015
CPE604
GROUP MEMBERS:
MUHAMMAD NASRUL BIN BOJY (2014662104)
MOHAMMAD AMIR HAKIM BIN RUSLI (2014294432)
HANEARYTHA LITAD CHARLES (2014679702)
CHE MUHAMMAD FAIZ BIN CHE LAH (2014807942)
NURADILLA BT IRWAN SHAH JOSEPH (2014442236)

PRODUCTION OF LIQUID
FUEL FROM PE WASTE
GROUP MEMBERS:
MUHAMMAD NASRUL BIN BOJY (2014662104)
MOHAMMAD AMIR HAKIM BIN RUSLI (2014294432)
HANEARYTHA LITAD CHARLES (2014679702)
CHE MUHAMMAD FAIZ BIN CHE LAH (2014807942)
NURADILLA BT IRWAN SHAH JOSEPH (2014442236)

CHEMICAL PRODUCT
DESIGN

IDENTIFICATION OF NEEDS

heat homes
run the vehicles
power industry and manufacturing
produce electricity.

IDENTIFICATION OF IDEAS

Producing fuel from animals fat

Producing biofuel from waste cooking oil
Producing fuel from mix carbon dioxide
Producing fuel from lignocellulosic biomass
Producing fuel from algae
Producing of fuel using rubber
Use water steam as a fuel
Coconut oil as a fuel
Producing fuel from animal waste (biomass)
Producing of fuel from plastic waste

 SELECTION OF IDEAS
Screening
Scoring
Criteri

IDEAS

on

10

Score

+4

-1

+3

+2

+1

Rank

Criterion Weight

IDEAS
1

30%

30%

20%

10%

10%

+3

+1

+1

TotalScore

3.0

2.3

2.5

2.5

Rank

Criteria 1: The availability of the feed stock

Criteria 2: The cost of the feed stock
Criteria 3: The ratio of the product to the feed stock
Criteria 4: Environmental friendly of the process.
Criteria 5: The quality of the feed stock

MARKETINGSTRATEGY

Produce 4000L per day x 382 Batch

1056.688 gallon per day
Supply to Oil and Gas Company to refining the pyrolysis oil
On average, U.S. refineries produce about 19 gallons of motor gasoline12 gallons
of diesel fuel, and 4 gallons of jet fuel from a 42 gallon barrel of crude oil. (U.S
Energy Information Administration, November 2015)
HIGH OPERATING COST
REQUIRE LARGE NUMBER OF EMPLOYEE
MUCH SPACE OF LAND REQUIRED

SELECTION OF PROCESS
ROUTES

CHEMICAL REACTION INVOLVE

PYROLYSIS

Chemical Reactions in Pyrolysis Process

1)Initiation

Sketch of random scission reaction in plastic pyrolysis.

2)

Propagation

Illustration of mid chain -scission reaction.

Illustration of end chain -scission reaction

3) Termination

Sketch of the termination reaction or radical

combination reaction

STOICHIOMETRIC EQUATION

KINETIC-CONTROLLED

The Pyrolysis of hydrocarbon polymers is a very

complex process, which undergo hundreds of
reaction and products.
Thus, the Pyrolysis reaction is a kinetic-controlled
as there are a number of factors that will affect
the process and the reactions such as catalyst
and reactor type.

CATALYST

The type of catalyst that is used in the process is

zeolite.

EXCESS REACTANT

No excess reactant that is fed into the reaction

system in order to yield a higher yield.
The choice of using PE waste compare to other
type of plastic is the decision that is made in
order to yield greater yield of the desired product
which is the liquid fuel.

COMPETING REACTIONS AND SELECTIVITY

the difference of various functional group bond
energies in the lignin induces the different functional
group that is broken under different temperature and
therefore, the entire pyrolysis process displays many
pyrolysis competing reactions
the selectivity in pyrolysis process to obtain the liquid
product which is the liquid fuel can be controlled by
tuning of the acidity and pore size of catalyst into a
high acidity in pH and also with big pore size of
catalyst

SPECIAL CONDITION OF TEMPERATURE AND pH

pyrolysis is by subjected to a special

condition of temperature which is a
high temperature of about 400 oC in the
absence of oxygen
high acidity in order to yield more
production of liquid fuel production.
SINGLE PASS CONVERSION
99% conversion

CHEMICAL REACTOR
DESIGN

Heuristics for Reactor

1.

2.

Rule 3: The optimum proportions of

stirred tank reactor are with liquid level
equal to the tank diameter, but at high
pressures slimmer proportions are
economical.
Rule 6: Batch reactions are conducted in
stirred tanks for small daily production
rates or when the reaction times are
long or when some condition such as
feed rate or temperature must be
programmed in some way.

3.

Rule 11: The effect of temperature on

chemical reaction rate is to double the
rate every 10 oC.

4.

Rule 12: The rate of reaction in a

heterogeneous system is more often
controlled by the rate of heat or mass
transfer than by the chemical reaction
kinetics.

The total volume of the Volume of

batch reactor is 12 m 3.

The volume of reactor is based on

the real size reactor that used in
the pyrolysis process by companies
that produce the pyrolysis oil.

Every 1 tonne of feed, 3 m 3 of

reactor size will be used. Thus, for 4
tonne of feed, 12 m 3 of the batch
reactor is used.

The reactor is cylindrical shape and

made of carbon steel. The reactor
has a single inlet and outlet stream.

The reaction is helped with the

presence of catalyst which is
zeolite.

RECYCLE STRUCTURE

FEEDSTOCK TO BE RECYCLE
In the pyrolysis, the reaction
converts the 99% of the PE waste
into products consists of pyrolysis oil
and gas. Thus, the 1% of the
unreacted PE left in the batch reactor
will be recycled into the next batch.
The 40 kg unreacted PE will be mixed
with the feed of the next batch. Thus,
the next batch will only requires only
requires 3960 kg of the PE waste.

RECYCLING OF PE WASTE

RECYCLE SYSTEM

DOWNSTREAM
PROCESSING

SEPARATION PROCESS
The separation system process to be used in pyrolysis started from
the reactor.
This is because there is separation process occurs in the reactor itself.
The separation system in the reactor resembles the simple batch
distillation.
In pyrolysis, the resulting oil which is the mixture of liquid
hydrocarbon is continuously distilled once the waste plastic inside the
reactor are decomposed enough to evaporate upon reaching the
reaction temperature.
The separation process produces a pure stream of product to
undergone further process which is purification process while leaving
the pure unreacted in the reactor to be recycled.
The unreacted PE waste is easily recovered and put into the storage
tank. The unreacted PE waste will then mixed into the feed of the next
batch of the pyrolysis of the PE waste.

MATERIAL BALANCE SEPARATION

SYSTEM

PURIFICATION PROCESS
The purification process in this is by using a condenser and a
separator vessel.
The pyrolysis process produces products in gas phase.
After the pyrolysis oil in gas phase exits the reactor, some of
the hydrocarbons with high boiling point will undergo
condensation process in a water-cooled condenser.
The liquid hydrocarbons which are the liquid-fuel product are
then collected in a storage tank through a receiver tank.
The separation system produces pure stream of the products
and by-products due to huge difference in their boiling point.
The liquid-fuel has a high boiling point which is above 100 oC
while the gas-fuel has the boiling point below 0 oC. Thus, the
liquid-fuel is assumed to be 100% separated from the
uncondensed gaseous.

MATERIAL BALANCE PURIFICATION

SYSTEM

DESIGN OF SEPARATION &

PURIFICATION SYSTEM

DESIGN OF SEPARATION &

PURIFICATION SYSTEM
The size of the batch reactor which is design as part of the
separation system is 12 m3.
The size of the process vessel or separator is determined through the
heuristics in Table 11.6.
The separator provides surge capacity or separation of entrained
phases and the size is relatively small.
In the separation process, the product which is the pyrolysis oil is
separated in gas and liquid phase. Thus, the separator is in vertical.
The optimum ratio of length to diameter = 3, but the range is 2.5 to
5 is common.
Assume that 60% of liquid fuel volume is going to fill up the tank.
Thus, the volume of the process vessel is going to be 6.7 m 3.
From the ratio given, the length of the process vessel will be 4.35 m
and the diameter is 1.4 m to give the ratio of length to diameter 3.

CAPITAL COST ESTIMATION

BARE MODULE COST

TYPEOFEQUIPMENT
SHREDDER

REACTOR

HEATEXCHANGER

STORANGETANK

PROCESSVESSEL

NUMBEROF
EQUIPMENT

BAREMODULECOST(RM)

40320.00

1302600.6

469957.12

1571691.61

179877.76

5606095.82

BAREMODULE
TOTAL BARE MODULE
COST,
CBM2015(RM)

RM6615193.07

MANUFACTURING COST

Cost Of Raw Materials

Polyethylene waste
=4000 kg x x x x 0.92
=RM 307,017.14 per year
Zeolite catalyst
1 ton of zeolite catalyst = RM
950
per year
Total annual cost of raw
material
= Polyethylene waste + Zeolite
catalyst
= RM 307,017.14 + RM 950
= RM 307967.14

Cost Of Operating Labor

NOL =(6.29 + 31.7P2 + 0.23Nmp)0.5
=[6.29 + 31.7(0)2 + 0.23(5)]0.5
=2.73

335 operating days x = 48 weeks

48 x 7 = 336 shifts per operator per year

335 x = 1005 shifts/year

1005 x = 3 operators

Operating Labor = (2.99) (2.73)

= 8.16
= 8 persons

Annual cost of operating labor = 8 persons

x RM 21,600
= RM 172,800/year

Cost Of Utilities
Utility

Description

Chilled water

Process cooling water

Cost RM/year

1500.00

at 30oC

Electricity

80000.00

Total per year

RM 81500.00

Value used

Cost item
Direct Manufacturing cost

a.

Raw materials

Cwt

b.

Utilities

Cut

c.

Operating Labor

d.

Direct supervisor and clerical

Col
0.2Col

labor
e.

Table of
Multiplication
Factors for
Estimating
Manufacturin
g Cost

0.05FCI

Maintenance and repairs

f.

Operating supplies

g.

Laboratory charges

h.

0.005FCI
0.2Col
0.01COM

Patents and royalties

Total Direct Manufacturing Cost = CRM +CUT + 1.40COL + 0.01COM

0.055FCI

Fixed costs

a.

Depreciation

0.1FCI

b.

Local taxes

0.02FCI

c.

Insurance

d.

Plant overhead costs)

0.01FCI
0.5(COL+0.2COL + 0.05FCI)

Total Fixed Manufacturing Cost = 0.6COL + 0.055FCI + depreciation

General expenses
a.

Administration costs

b.

Distribution and selling costs

c.

0.15(COL+0.2COL + 0.05FCI)
0.10COM

Research and development

0.05COM

Total General Expenses = 0.18COL + 0.0075FCI + 0.15COM

Total Direct Manufacturing Cost

DMC =CRM +CUT + 1.40COL + 0.01COM + 0.055FCI
=RM [307967.14 + 81500 + 1.40(172,800) +0.01(1929949) +
0.055(6,402,937.31)]
=RM 1,002,848.18

Total Fixed Manufacturing Cost

FMC =0.6COL + 0.055FCI + depreciation
=RM [0.6(172,800) + 0.155(6,402,937.31)]
=RM 1,096,135.28

Total General Expenses

GE =0.18COL + 0.0075FCI + 0.15COM
=RM [0.18(172,800) + 0.0075(6,402,937.31) + 0.15(1929949)]
=RM 368618.38

Cost Of Manufacturing
COM
COM

= DMC + FMC + GE
=1.19(CRM +CUT) + 2.595COL + 0.259FCI

=RM2,570,243

Cost Of Manufacturing (without

depreciation)
COM,d =1.19(CRM +CUT) + 2.595COL + 0.159FCI
=RM1,929,949

PROFITABILITY ANALYSIS

Estimation Annual Revenue

Product = 4000 L / batch Liquid-fuel
4000 L x RM 2.70/L = RM 10,800 per batch
RM 10,800 x 382 batch/ year= RM 4,125,600 per
year

Discounted After Tax Cash Flow