ANALYSIS OF DIESEL FUEL FROM PLASTIC WASTES BY CATALYTIC PYROLYSIS

2012 ANALYSIS OF DIESEL FUEL FROM PLASTIC WASTES BY CATALYTIC PYROLYSIS

MECHANICAL ENGINNERING 2K8 BATCH B.I.T SINDRI 4/30/2012

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BIT SINDRI The Project “Analysis of Diesel produced by pyrolysis of Plastic Wastes” has been undertaken by the following students of 4th year Mechanical Engineering from BIT SINDRI

Name

Roll No.

Kartik Pd. Rajak

080039

Kumar Abhishek

080041

Manish Kumar

080048

Mannu Choudhary

080050

Navneet Kumar

080057

Nikhil Hansda

080058

Nikhil Kr. Jha

080059

Niraj Kumar

080061

Pawan Kumar

080064

PrakashRanjan

080069

Tarun Kr. Singh

080099

Under the able guidance of Prof. Rajan Kumar

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INDEX 1. Introduction……………………………………………………………………………………… 06 2. Acknowledgement ……………………………………………………………………………. 07 3. Energy Crisis Scenario In India…………………………………………………………… 08 4. Pyrolysis  Plastic waste management……………………………………………………..09  What Is Pyrolysis?.......................................................................10  Pyrolysis as recovering value from wastes……………………………….11  Pyrolysis of Plastic Wastes……………………………………………………….12  Flow Chart for Pyrolysis……………………………………………………………13 5. Pyrolysis Process  Process Description………………………………………………………………… 14  Benefits of Pyrolysis………………………………………………………………… 17 6. Distillation of Crude Plastic Oil  Normal Distillation…………………………………………………………………… 18  Vacuum Distillation……………………………………………………………………19 7. Fuel Properties  Analysis of Raw Material ( MSW)……………………………………………… 21  Analysis of Poly-crack Fuel Collected………………………………………… 21  Analysis of Diesel collected from Plastic Wastes…………………………22

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8. Diesel engine  Definition of Diesel Engine………………………………………………………….23  Working of Diesel Engine…………………………………………………………….23  Experimental Apparatus……………………………………………………………...24

9. Experimental Apparatus  Specifications of Diesel Engine…………………………………………………….25  Rope Break Dynamometer…………………………………………………………..26  Measurement of Air consumption by Air Box Method………………….28 10. Engine Performance Calculations  Calculation of load percentage…………………………………………………….30  Calculation of Mass flow rate of fuel…………………………………………….31  Calculation of Heat Input………………………………………………………………31  Calculation of Thermal Brake efficiency………………………………………..31  Calculation of Brake specific fuel consumption……………………………..32  Measurement of Air consumption………………………………………………..32  Calculation of volumetric efficiency………………………………………………33  Calculation of Brake Mean effective pressure……………………………….34  Calculation of Air-Fuel ratio…………………………………………………………..34 11. Table of Experimental Records  Diesel as Fuel at different Load %....................................................35  5% Blend at different Load %...........................................................39

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 10% Blend at different Load %.........................................................43  20% Blend at different Load %.........................................................47

12. GRAPHS  Brake Thermal Efficiency versus Load Percentage………………………..51  Brake Thermal Efficiency versus Brake Power………………………………52  Brake Specific Fuel Consumption versus Load %.............................53  Volumetric Efficiency versus Load %...............................................54  Brake Specific Fuel Consumption Vs. Brake Power……………………….55  Volumetric Efficiency versus Brake Power……………………………………56  Brake Power versus Mean Effective Pressure……………………………….57  Brake Power versus Exhaust Temperature……………………………………58

13. Smoke-Meter  General application areas…………………………………………………………….59  Specific application areas……………………………………………………………..59  Basic operating principle………………………………………………………………59  Mechanical description…………………………………………………………………60  Unit……………………………………………………………………………………………… 60

14. Smoke-Meter readings  Reading of Smoke-Meter using different blends…………………………..61  Graph of Smoke-meter versus Load %.............................................62 15. Inference…………………………………………………………………………………………………63 16. Conclusion……………………………………………………………………………………………….65

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INTRODUCTION The Rapid depletion of fuels and their ever increasing costs have led to an intensive search for alternative fuels. The most promising technology in today’s world is the Recycling of waste materials and their value- addition. Our project deals with understanding the basic concepts of pyrolysis technique i.e. the thermo chemical decomposition of organic material at elevated temperatures in the absence of oxygen. It also deals with concept of crude oil refining and distillation to separate the various fractions such as naphthalene, petrol, diesel, kerosene. Etc. We also recorded the emission (the amount of blackness) produced during the engine testing for different blends. The main theme of the project is to test the fuel on engine in order to determine its efficiency and compare it with different blend mixture of diesel with the diesel fraction produced by the pyro- crack/ pyrolysis process in-order to select the best blend. This is important because we need to develop better, cheap and clean alternative fuels for a greener future.

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ACKNOWLEDGEMENT First of all, we would like to express my heartfelt thanks and immense respect to Mr Nitin Bondal and Mr T.R. Rao (of Sustainable Technologies & Environmental Projects Pvt Ltd.) whose scholarly guidance and help to provide us the facilities to carry out the poly-crack technology and produce plastic fuel from the waste plastic materials. We are indebted to him for his patient listening to all my queries and his valuable help in teaching me the basics of poly-crack technology. I would also like to express our sincere gratitude to Mr. A.K. SINHA of CIMFR Digwadih to guide us during the distillation process. Lastly, I would like to thanks my Professor In- Charge, Mr. Rajan Kumar who provided us the opportunity to work in this new field of development of alternate fuels to replace diesel and gasoline.

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Energy Crisis Scenario in India With high economic growth rates and over 17 percent of the world’s population, India is a significant consumer of energy resources. India, at 1.17 billion people, is the second most populated country in the world. Despite the global financial crisis, India’s energy demand continues to rise. India consumes its maximum energy in Residential, commercial and agricultural purposes in comparison to China, Japan, Russia, EU-27 and US.

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Plastic Waste Management The Polymer Energy system is an award-winning, innovative, proprietary process to convert waste plastics into renewable energy. Plastics play a very important role in our daily lives. Throughout the world the demand for plastic, particularly plastic packaging, continues to rapidly grow. Previous waste management methods such as landfill disposal, incineration, and recycling have failed to provide opportunities for the complete reuse of plastic waste. The Polymer Energy system uses a process called catalytic pyrolysis to efficiently convert plastics to crude oil. The system provides an integrated plastic waste processing system which offers an alternative to landfill disposal, incineration, and recycling—while also being a viable, economical, and environmentallyresponsible waste management solution.

The Polymer Energy system uses a process called which offers an alternative to landfill disposal, incineration, and recycling—while also being a viable, economical, and environmentally-responsible waste management solution.

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What is Pyrolysis? Pyrolysis is a thermo chemical decomposition of organic material at elevated temperatures in the absence of oxygen. Pyrolysis typically occurs under pressure and at operating temperatures above 430 °C (800 °F). The word is coined from the Greek-derived elements pyr "fire" and lysis "separating". Pyrolysis is a special case of thermolysis, and is most commonly used for organic materials, being, therefore, one of the processes involved in charring. The pyrolysis of wood, which starts at 200–300 °C (390–570 °F), occurs for example in fires or when vegetation comes into contact with lava in volcanic eruptions. In general, pyrolysis of organic substances produces gas and liquid products and leaves a solid residue richer in carbon content. Extreme pyrolysis, which leaves mostly carbon as the residue, is called carbonization. The process is used heavily in the chemical industry, for example, to produce charcoal, activated carbon, methanol, and other chemicals from wood, to convert ethylene dichloride into vinyl chloride to make PVC, to produce coke from coal, to convert biomass into syngas and bio-char, to turn waste into safely disposable substances, and for transforming medium-weight hydrocarbons from oil into lighter ones like gasoline. These specialized uses of pyrolysis may be called various names, such as dry distillation, destructive distillation, or cracking. Pyrolysis differs from other high-temperature processes like combustion and hydrolysis in that it does not involve reactions with oxygen, water, or any other reagents. In practice, it is not possible to achieve a completely oxygen-free atmosphere. Because some oxygen is present in any pyrolysis system, a small amount of oxidation occurs.

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PYROLYSIS AS RECOVERING VALUE FROM WASTE With an increase in population, urbanization and technology advancement, the amount and type of waste generated by various sectors is rapidly increasing, causing negative impacts on health and the environment. Pyrolysis is the thermal decomposition of waste into gas and solid phases in the absence of the external oxygen supply. The process takes place under the temperatures typically around 500°C. The gaseous product of pyrolysis can undergo the following transformations in downstream processes:  

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Cooling down followed by oil condensing; liquefaction is applicable for a limited number of feedstock, such as plastics or rubber. Cracking and cleaning in order to be used as fuel in a gas engine; pyrolysis gas conditioning is a complicated problem and additional drawback is that further treatment of the pyrolysis char will be performed at the high temperatures around 1500 C. Secondary combustion and generation steam in boiler, which consequently will be sent to steam turbine to generate electricity.

Some of the advantages of pyrolysis are that the pyrolysis process is relatively insensitive to its input waste, combustion products associated with the burned solid waste are not generated, and dioxins formation can be efficiently prevented.

Application

Waste-toEnergy

Feedstock to pyrolysis system

Products of pyrolysis

 Municipal Solid Waste (MSW)

 Electrical energy

 Waste plastics

 Steam

 Medical waste

 Black carbon

 Rubber and tires

 Oil

 E-waste

 Non-oxidized metals

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Pyrolysis of Plastic wastes All plastics are polymers manufactured from the petroleum lighter like propylene, mostly containing carbon and hydrogen and few elements like chlorine, nitrogen etc. Polymers are made up of molecules called as monomers which combine and form single molecule called polymer.

ends other small large

When this long chain of monomers breaks at certain points or when lower molecular weight fractions are formed this is termed as degradation of polymer. This is the reverse of polymerization. In the process of conversion of waste plastic into fuels random DePolymerization is carried out in a specially designed Reactor in the absence of oxygen and in the presence of a proprietary catalyst. The maximum reaction temperature is 3500C. The plastics are converted completely into value added fuel products. You can recycle: Polypropylene - trash cans, tie bands, DVD cases, junk food wrappers, etc. Polyethylene - wrapping paper, super market bags, clothes, plastic bottle caps, etc. Polystyrene - Styrofoam, etc.

All plastics including Polyethylene, Polypropene, Polystyrene, PVC, PVA, Industrial plastics, automobile fluff, bio-medical waste etc. Polyethylene and polypropylene are pure hydrocarbons. However, they are arranged in long chains. If you chop those chains into shorter ones, you get oil. If you chop them even shorter, you get diesel. If you chop them again, you get gasoline and eventually burnable gas.

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FLOW CHART FOR PYROLYSIS OF PLASTIC WASTES INTO FUEL COLLECTION AND SEGREGATION OF PLASTIC WASTES

STORING OF PLASTIC WASTES

SHREDDING OF WASTES

FEEDING INTO HOPPER

FLOW OF WASTES INTO HEATING VESSEL IN PRESENCE OF CATALYST

MOVEMENT OF LIQUID-VAOUR INTO CONDENSER

TAPPING OF LIQUID FUEL (PRODUCT)

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PROCESS DESCRIPTION  Brief plant layout and operational procedure The existing plant has a capacity to process 25 to 50 kg of different organic wastes per batch operation. The plant is installed on a small MS rectangular structure with centralized electrical control panel. The cooling water desired for condenser cooling is provided by water circulation. The gases generated during the plant processing are burnt nearby on the vent pipe as soon as they catch fire during material processing. The plant is loaded with the weighed quantity of organic wastes. The loading point is closed after the completion of material loading in the reactor. Heating from the control panel is then started gradually. The temperature profile of each batch is logged. As soon as the temperature reaches 150°C the gases generated during the process are passed over a patented catalyst cartridge and allowed to pyro-crack. The gas passes through the condenser where water and liquid fuel condensed is separated out and the gas is allowed to vent through the vent line. The vent line is ignited and the gas is allowed to burn. The liquid collected in the condenser is periodically drained and at the end of the run oil and water are separated out. The total process lasts for about 4-5 hours. At the end of each operational cycle the residue is separately collected and weighed.

 Power and utilities consumption: Power consumption of the plant is to the tune of 6kW-hr which includes heating as well as water circulation pump. Water required for condenser is currently recycled by water circulation pump from main storage tank.

 Waste generation and disposal methods: The carbonaceous residue is collected in a gunny bag. Same is proposed to be used as solid fuel similar to coke. The water collected along with oil will be separated out by a different process. There is good amount of calorific value in the gas produced which is notified by distinct blue color flame. This gas has a potential to be used as fuel.

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MAIN PYROLYSIS PLANT

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The figure on the left is the temperature control device of the main heating vessel of the pyrolysis unit. The figure below is the condenser of the machine which is water-cooled.

MAIN PARTS OF PYROLYSIS PLANT

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Benefits of Pyrolysis: Waste is one of the major challenges which modern world is facing today. Every year billions tons of waste are generated and these amounts are rising steadily. Some major wastes which affect our environment are:       

Municipal Solid Waste (MSW) Different types of plastics Old tyres and rubber Auto Shredder Residue (ASR): plastics, rubber, fabrics, wires, etc. Organic waste: wood chips, saw waste, oil sludge, paper pulp sludge, poultry litter Medical waste from hospitals Electronic waste: computer boards, cables and wires

Wastes such as MSW, electronic-waste, scrap tyres are currently either difficult to recycle or not 100% recyclable, while other waste such as medical waste is not recyclable and shall be disposed. Another typical example is goods packaging (e.g. food) when plastic attached to other materials (aluminum / polymer laminate). Pyrolysis has a number of important advantages over incineration. 

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The pyrolysis system for treatment of MSW and other wastes demonstrates excellent practical performance in controlling the emission of harmful substances such as dioxins with levels dramatically lower than regulation values. The pyrolysis facility is self-sustainable, i.e. fuel is required only for start-up operations. Steam and/or electricity generated during operation is further supplied outside of the facility to the customers. The pyrolysis plant does not produce waste water effluent from the gas cleaning system. Along with this obvious environmental advantage it also makes the system less expensive. Another environmental aspect is the reduction of the residuals to be sent for landfill disposal. Some remaining non-toxic ashes can also be used in the building industry. Recovered Metals are non-oxidized and can be further used. Can treat both low calorific and high calorific waste.

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NORMAL DISTILLATION OF CRUDE PLASTIC OIL After manufacture of crude plastic oil by using the poly-crack technology of Sustainable Technologies & Environmental Projects Pvt Ltd. we had to separate its different fractions. For this purpose we had to undertake its normal distillation under atmospheric conditions up to 150°C and then normal distillation under vacuum pressure.Distillation is a method of separating mixtures based on differences in volatilities of components in a boiling liquid mixture. Distillation is a unitoperation, or a physical separation process, and not a chemical reaction. The application of distillation can roughly be divided in two groups:  Laboratory scale  Industrial distillation The main difference between laboratory scale distillation and industrial distillation is that laboratory scale distillation is often performed batch-wise, whereas industrial distillation often occurs continuously. In batch distillation, the composition of the source material, the vapors of the distilling compounds and the distillate change during the distillation. In batch distillation, a still is charged (supplied) with a batch of feed mixture, which is then separated into its component fractions which are collected sequentially from most volatile to less volatile, with the bottoms (remaining least or non-volatile fraction) removed at the end. The still can then be recharged and the process repeated.

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In continuous distillation, the source materials, vapors, and distillate are kept at a constant composition by carefully replenishing the source material and removing fractions from both vapor and liquid in the system. This results in a better control of the separation process.

VACUUMDISTILLATION Some compounds have very high boiling points. To boil such compounds, it is often better to lower the pressure at which such compounds are boiled instead of increasing the temperature. Once the pressure is lowered to the vapor pressure of the compound (at the given temperature), boiling and the rest of the distillation process can commence. This technique is referred to as vacuum distillation and it is commonly found in the laboratory in the form of the rotary evaporator. This technique is also very useful for compounds which boil beyond their decomposition temperature at atmospheric pressure and which would therefore be decomposed by any attempt to boil them under atmospheric pressure.

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1: Stirrer bar/boiling chips 2: Still pot 3: Fractionating column, preferably vacuum jacket insulated 4: Thermometer/Boiling point temperature 5: Teflon tap 1, distillate collecting tap 6: Cold finger 7: Cooling water out 8: Cooling water in 9: Teflon tap 2, still isolation tap 10: Vacuum/gas inlet 11: Teflon tap 3, distillate isolation tap 12: Still receiver

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FUEL PROPERTIES  ANALYSIS OF RAW MATERIAL (MIXED PLASTIC WASTES) Properties

UOM

Results

Appearance

Visual

Mixed plastics

Loss of drying

%W/W

0.5

Loss of ignition

%W/W

94

Calorific value

%W/W

4530

 ANALYSIS OF POLYCRACK FUEL COLLECTED PROPERTIES

UNITS

RESULTS

INITIAL BOLING POINT

°C

115

DENSITY @°C

G/ml

0.864 @30

GROSS CALORIFIC VALUE

Cal/G

10800

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 ANALYSIS OF DIESEL FROM PLASTIC FUEL PROPERTY

METHOD

UNIT

RESULTS SPECIFICATIONS OF DIESEL

DENSITY @ 15°C

ASTM 24052

G/ml

0.7729

SULPHUR CONTENT

ASTM 2622

Mg/kg

80.00

FLASHPOINT TEMPERATURE

ASTM D93A

°C