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Industrial Design Problem_1
To establish an efficient Pilot Plant Design to convert waste plastic to Fuel (energy).
TOPIC
Submitted By:~
Mohit Rouniyar
Mukul Anand Team Name:~ SPARX
Contents
Introduction
Plastics Analysis
Pre-treatment Process
Process Flow Diagram
Catalyst Analysis
Pyrolysis Reactor
Stimulation on Hysys
Material/Energy Balance
Economics Analysis
References
Waste Plastics To Fuel
Introduction
Plastics are synthetic organic materials produced by polymerization.
Waste plastics are one of the resources for fuel production because of its high heat of
combustion.
Plastics Type are Thermosetting, Thermoplastics,
Elastomer.
Most content of plastics are Polyethylene,
Polystyrene, Polypropylene, PVC, other.
Waste Plastics Analysis
Plastics and Petroleum derived fuels are Hydrocarbon
Plastics content longer carbon chains
Following Chart are comparison for calorific value of Petroleum products and Plastics
Material Calorific value (MJ/kg)
Polyethylene 46.3
Polypropylene
46.4
Polystyrene 41.4
Polyvinyl chloride 18.0
Coal 24.3
Liquefied Petroleum Gas 46.1
Petrol 44.0
Kerosene 43.4
Diesel 43.0
Heavy Fuel oil 41.1
Light Fuel oil 41.9
Block Diagram
Treatment of Impurities
Washing with Water for the removal of impurities like Sand, Mineral, Bio-Mass
Shredding of Waste Plastics for reducing the size
Drying for removal of waste water
Removal of Oxygen by introducing Purge Nitrogen Environment
Removal of Poly Vinyl Chloride after Pre Heating Process by the addition of NaOH
as solvent in scrubber
Removal of Benzoic Acid by De-chlorination
Pre Treatment Process
CATALYST ANALYSIS
Amorphous Almuino - Silicate is proposed
Meso - Structure having relatively low surface area
Pore size and Volume
Low Acid strength as compared to Zeolites.
Shows great activity on cracking of PP
Liquid fuel conversion is about 86%
The residual level is <8 wt % at 500°C.
Contd… YIELD(wt% FEED)
ZSM-5 USY MOR SAHA Silicates
PS PVC PS PVC PS PVC PS PVC PS PVC
Gases 4.25 30.64 3.84 28.11 1.85 31.07 0.72 30.29 0.05 34.49
Styrene 67.52 n.d 61.54 n.d 58.52 n.d 75.45 n.d 72.12 n.d
Other Aromatics
21.39 n.d 16.6 - 31.22 n.d 15.57 - 22.52 .
HCl n.d 54.52 n.d 55.87 n.d 55.52 n.d 55.45 n.d 56.2
Residue 6.84 14.81 18.02 16.02 8.41 13.41 8.26 14.26 5.31 9.31
n.d: Not Detectable
Stimulation Analysis
The composition of raw material (plastics) is PE:40%, PP: 40%, and PS: 20%.
Material balance of all streams are in steady state condition,
Vapors behave as ideal-gas and liquids behave as ideal-solution,
No accumulation of mass, and reaction only takes place inside the reactor, .
Enthalpy balance is based on the first law of thermodynamics
Work done on the system by its surrounding are zero.
Energy and Material balance data have been extracted from HYSYS 3.2 simulation
Process Flow Diagram
Overall Process Flow Diagram
Pyrolysis Reactor
Fluidized Bed Reactor
Proposed Material of Composition Stainless Steel
Addition of Duramunium and Mangnese
PROCESS HEATING RATE RESIDENCE
TIME
TEMPERATURE(°C) TARGET
PRODUCTS
SLOW
CARBONIZATION
VERY LOW DAYS 450-600 CHARCOAL
SLOW PYROLYSIS 10-100K/MIN 10-60 min 450-600 Gas, Oil, Char
FAST PYROLYSIS Upto 1000k/s 0.5-5s 550-650 Gas, oil, (char)
FLASH PYROLYSIS Upto 10000k/s <1 s 450-900 Gas, oil, (char)
Design of Pyrolysis Reactor
Product Analysis
Yield(w/w%) Polyethylene Polypropylene Polystyrene
Cracking Temperature
450°C 450°C 320°C
Gases 18.3 15.7 4
Liquids 81.7 84.2 93
Char >1 >0.25 3
Dominant Products
PE is n-alkenes,1-alkenes
PP is Cyclo-hexane
PS is Styrene
Chemical Reaction
Material Balances
Energy Balances
Economic Analysis
Type of Equipment Cost in USD($)
Storage Tank 1,713,600
Conveyor 977,300
Distillation Column 226,400
Total Estimation Cost 3,349,100
References
Wikipedia
A text book on Chemical Reaction Engg by Octave Levenspiel
A text book of Chemical Technology by Dryden’s
Thesis paper on pyrolysis done by Feng Gao and many more.
…THANK S
?
Query
Robust Design