Shri Ram Centennial School: Topic – Plastic 2 Fuel – Pyrolysis Process

SHRI RAM CENTENNIAL SCHOOL SESSION 2018-19

SENIOR BAL VIGYAN – COMMERCE SUB THEME- WASTE MANAGEMENT

TOPIC – PLASTIC 2 FUEL – PYROLYSIS PROCESS PRESENTED BY-

ACHAL DOSI JAHNVI SARDA RHITVIK VERMA VIDUSHI KESHARWANI

PLASTIC WASTE

FACTS ABOUT PLASTIC

DISADVANTAGES OF PLASTIC Hazardous Waste

Polymers and Non Biodegradable Toxin Carriers Dangerous if Consumed

RECYCLING GETTING FUEL FROM USED PLASTICS

SCOPE

Being a zeroresidue, user-friendly and environment -protecting technology, It promises to gobble up plastic waste.

Plastics to Fuel technologies are expected to be particularly helpful in island nations where fuel prices are high and landfill options are limited.

Communities now have the potential to create some of their own fuel locally, providing economic and environment al benefits.

Recovering raw materials from the waste stream is the future.

With plastic consumption set to double in the next 20 years, recycling must be profitable to make a difference.

WHAT WE HAVE LEARNED FROM COUNTRIES AROUND THE WORLD

In Maharashtra’s Pune, Medha Tadpatrikar and Shirish Phadtare , achieved significant success in converting plastic waste to fuel, that too without the aid of a fancy laboratory or a scientific background. An extensive research by the two women who deducted that usable fuel could be obtained from plastics, using the mechanism of thermos-catalytic depolymerisation. Subsequently, Rudra Environmental Solutions was founded and in 2010, the first plastic to fuel conversion machine was set up in Pune.

Goa has been instrumental in converting plastic waste into fuel. Goa generates nearly 66 metric tonnes of plastic waste every day. Two plants in Goa’s Bicholim and Sonsoddo have been setup under the public private partnership (PPP) model with Bangalore-based M K Aromatics Ltd since 2016.

EXISTING PROJECTS IN INDIA In Hyderabad, the waste to energy company Ventana announced the setting up of multiple waste to fuel plants, in collaboration with Ramky Environment, a waste management service. The announcement was made in January 2017. For over a year now, 45-year-old Satish, a long-time resident of Hyderabad, has been involved in turning 'dead' plastic, into usable fuel.

Footed in the year 2007,in Indore Heera Energy System is one of the eminent names of the industry thoroughly engrossed in manufacturing a wide variety of products which include Pyrolysis Plant, Waste Plastic To Oil Plant, Light Diesel Oil Filtration Machine and many more.

FIELD VISIT

Jahnvi Sarda of Class XI with Director of SNG Unicorns, Mr. Sudhanshu Dilliwal

Jahnvi Sarda of Class XI with Director of Indore Caps Pvt Ltd Mr. Prashant Barod

QUESTIONNAIRE Question

What type of plastics can be used in the Pyrolysis process?

Response

All kinds of plastic can be recycled, but they all have different oil yielding capacity. HDPE & Medical Grade Plastic have maximum oil yield up to 80% and other plastics like PVC & PET have oil yield capacity between 50-60%. There is one more difference between these plastics, Polythenes doesn’t break easily and solidify below the temperature of 20°C, as it has paraffin. Whereas Polypropylene breaks easily and doesn’t have any paraffin so you will get liquid fuel.

Question

Is the waste plastic easily available?

Response

The plastic wastes are easily available in cities where more industries are operating. Industrial plastic wastes are cheaply available and are easily processed.

Question

What is the cost of raw material?

Response

It is available at a price of Rs 12-15/kg and the conversion cost is Rs 10.

Question

At what Price do you sell your this Oil?

Response

We will sell diesel at a price of Rs 42/l.

Question Response

So, do you sell only diesel? No, in the Pyrolysis process the oil obtained is distilled to get diesel. Also we get a byproduct that is carbon sludge. The diesel is sold to casting industries whereas carbon to cement factories.

Question

Who are your Potential buyers?

Response

Our products are mainly sold to industries like Mahindra motors, Eicher motors and VE commercials and the byproduct has many potential buyers like cement factories, road and highway developers.

Question

What is the capacity of your machine and at what price you purchased it?

Response

We have a plant capacity of 10 tonnes purchased at a price of Rs 30 lakhs.

Question

What was your experience in the initial years of setup? What challenges did you face?

Response

Just like many Pyrolysis plants in the city faced losses and shutdown their plant, we also incurred huge loss in the initial years and it was difficult for us to survive. But, we didn’t give up and adapted all the changes required to sustain in the market. We installed all the pollution control system in our campus guided by the pollution control authority. Eventually we developed a good market for our product and are now able to procure raw material at a much economical price.

Question

What Pollution control measures are required in the Plant?

Response

Look, when plastic is burned it gets converted into gas that has carbon content. The condenser cools down the temperature and converts gas into liquid. But, Some of the gas with shorter hydrocarbon length doesn’t liquefy and remain in gaseous state; This gas is released through a scrubber that absorbs the carbon content and release white smoke in the air thus controlling carbon emission in air.

INDIAN INSTITUTE OF PETROLEUM Indian Institute of Petroleum is one of the leading constituent laboratories of the Council of Scientific & Industrial Research. Established in 1960, the Institute is devoted to multidisciplinary areas of research and development in the downstream sector of hydrocarbon and related industry. In 2014, IIP developed a unique process of converting plastic waste like polyethylene and polypropylene, both together accounting for 60 per cent of plastic waste, can be converted to either gasoline or diesel. IIP’s technology also received a thumbs up from the Indian Railways two years back in April 2015, when then Railway Minister Dr Harsh Vardhan announced that the Railways would set up plants to manufacture diesel from plastic, which would be used for mechanical traction.

GOVERNMENT PROVISIONS Financial assistance is given for carrying out studies on waste to energy projects, covering full costs of such studies

Tax Benefit is provided on Recycling based production and sales

Financial assistance is provided on the capital cost for demonstration projects that are innovative in terms of generation of power from municipal/ industrial wastes

The Ministry of New and Renewable Energy has promoted the national programme for the recovery of energy from industrial and urban wastes, by providing various financial incentives.

Financial assistance is provided by way of interest subsidy in order to reduce the rate of interest to 7.5%, capitalized with an annual discount rate of 12 %. The assistance is routed through financial institutions (FIs)/ Lead FI of the project, etc.

ECONOMICAL BENEFITS OF RECYCLING

OBJECTIVES To establish the basis for the development and implementation of waste plastics recycling with the application of environmentally sound technologies

To raise awareness on plastic waste and its possible reuse for conversion into diesel or fuel. This could be generated and marketed at cheaper rates compared to that of the available diesel or oil in the market.

Demonstrate Integrated Approach at regional scale for recycle, recovery and safe disposal concepts.

To reduce the dependency on Gulf countries for fossil fuels, thereby contributing to the economic growth of the country.

Serve as venue for public awareness and environmental education on recycling

To promote resource conservation and green house gases.

Our Vision Is To Reduce The Dependency On Fossil Fuels And To Increase The Use Of Fuel From Plastic.

To Provide Integrated Knowledge Driven Eco Solution And Ensure Better Quality Of Life To Gen Next.

SOURCES & COLLECTION OF WASTE

PYROLYSIS PROCESS A New Way To Bring Value To Materials

LABORATORY WORK

DOMESTIC & MEDICAL PLASTIC WASTE

CHOPPED PLASTIC WASTE

LABORATORY SET UP FOR PYROLYSIS EXPERIMENT AT CHEMISTRY LAB IN OUR SCHOOL

NITROGEN IS ADDED

PLASTIC IS HEATED

OIL IS PRODUCED

PLASTIC PYROLYSIS PROCESS

PRODUCT • Fuel for Burners • Heavy Vehicles • Diesel Generators

DIESEL

FUEL OIL KEROSENE DIESEL PETROL

CHARCOAL • Fuel for Burners

• • • •

Road Construction Cement Factory Water Purifiers Candle Making

CHARCOAL

FUEL GAS

FUEL GAS

APPLICATION & FUTURE WORK

The oil produced is a substitute for furnace oil and LDO. Carbon is used by cement industry and brick kilns as a fuel for firing. Large or small scale industries can be set up to produce fuel locally at much cheaper rates directly benefiting the National economy and is also a step towards SWAACH BHARAT by recycling the waste plastic.

The obtained fuel could be utilized in diesel generators, vehicles such as tractors and also passenger vehicles such as cars.

The fuel has to be refined at the industrial establishments, based on the results of which small scale industry can be established

PACKAGING

Under innovative scheme we will become a participant of Going Green. We would store all its gasoline in Suitable Portable Containers They are reasonably robust They are not liable to break under normal conditions of use The escape of liquid or vapor is prevented Oil can be poured safely from them They are not unsteady when placed on a level surface.

LABELING Following details should be mentioned on the packing; Hazard warning sign “fuel” and “highly flammable”; Like the nominal capacity in litres; Manufacturer’s name; Date and Month of manufacture.

PRODUCTION PLAN Land Area (Plant and Warehouse)

3000 sq ft. / 280 sq meters.

Pyrolysis Plant

1 Machine Setup

Raw Material

10 Ton/ cycle

Labour

5-10 person

Power Requirement

20 KW

Water Supply

As Required

Transportation

Outsource

Packaging

5 liter. / 10 liter.

Process Brief For 1 KG Input And The Yield Of Output Input

Qty Kg

Rate per Kg

Amoun Output Qty (l) t (Rs)

Rate per liter

Amoun t (Rs)

Plastic

1.00

12.00

12.00

Petrol

0.600

37.50

22.50

Labour

5.00

Diesel

0.300

25.50

7.65

Service charge

2.50

Lube oil 0.100

15.00

1.50

Total

1.00

19.50

1.00

31.65

COST & PRICE Production Capacity

10 tonnes

Total Capital Cost Machine

25,00,000

Capital

1,50,000

Production CostWorking Capital

50,000 / month

Raw material

2,00,000 / month

Utilities

1,50,000

Profit %

20 – 25%

Output Price

30-40 Rs/ litre

TARGETED MARKET Diesel is used in Burners of Boilers, Furnaces, Hot Water, Hot Air Generators, Thermo Fluid Heater; Electric Generators and Diesel Pumps. Industries that use it are as follows: •Hospitals •Building material industries •Dairy industry •Petrochemical Industry •Steel Factory •Glass Factory Charcoal is in demand by Road construction companies, Cement Factory, Water Purifier and Candle producing firms. Also the Fuel gas is used in Burners in different industries.

STEEL FACTORY

GLASS FACTORY

CEMENT FACTORY

BRICK FACTORY

PROMOTION

SALES STRATEGY

It allows selling to consumers anywhere, anytime. It is economical way. Having an online presence helps makes sure that potential customers find your product information

It is the best tool for two-way communication. Salesman can provide necessary information to customer about company’s offer, and also can collect information from customer. Customer can actively involve with salesman to solve his doubts and objections

Trade shows offer budget friendly solutions to market your brand and sell your product. It helps to target new market and consumers. New relationships and deeper connections open channels for new sales leads.

REGISTRATION AND LICENSE Registeration with Ministry of Micro, Small and Medium Enterprises

No License is required to sell the product, as it is considered as Biosynthetic fuel, under India's National Policy on Biofuels

No objection Certificate from District Pollution Control Board

No objection Certificate from Municipal Corporation.

POLLUTION CONTROL MEASURES Industry shall use clean fuel such as LPG/PNG during startup of the reactor.

Industry shall ensure that there are no leakage from reactor and piping, so as to minimize fugitive emissions

The pyrolysis oil condensed from the vessel shall be collected in storage tanks located in earmarked areas. The pipelines shall be equipped with floating valves so as to avoid spillage due to overflow.

There shall not be spillage of pyrolysis oil in and around the factory premises.

Adequate fire fighting system shall be provided as per prevailing norms laid down by competent authority

Industry shall prepare on site and off site disasters management plan which shall be approved by competent authorities

SWOT ANALYSIS STRENGTH

WEAKNESS

• Waste plastic is converted into High Value • No Pollution is emitted • Availability of Fuel at lower price • Crude Oil & Gas can be used for generation of electricity

• Unstable quality of end product due to varied climatic conditions • Unauthorized waste collector • Non acceptance by users being a product from waste • Low Profit margins

OPPORTUNITYS

THREATS

• Sustained increasing market growth in coming years • Partner with reputed company that has far more marketing resources and sales channel

• Competition from renewable sources of energy • Increased competition • Strict pollution control measures is required at end use

CORPORATE SOCIAL RESPONSIBILITY

CSR

CONCLUSION Plastics present a major threat to today's society and environment. Though mankind has awoken to this threat and responded with developments in creating degradable bio-plastics, there is still no conclusive effort done to repair the damage already caused. In this regard, the catalytic pyrolysis studied here presents an efficient, clean and very effective means of removing the debris that we have left behind over the last several decades.