Chapter one

Introduction and Aim of project

1.1.Introduction
Plastic waste is regarded as a potentially cheap source of chemicals and
energy. Lots of us have encountered a variety of products that use plastic
materials today. As a result of the increasing level of private consumption
of these plastic materials huge amount of wastes are discharged to the
environment. Plastic materials are a type of material that cannot be
decomposed easily in a short period of time. Substantial quantities of
plastic have accumulated in the natural environment and in landfills.
Those wastes can be classified as industrial and municipal according to
their origins; these groups have different qualities and properties and are
subjected to different management strategies . The continuous increase of
waste plastic disposal is generating environmental problems worldwide.
The present rate of economic growth is unimaginable without saving of
fossil energy like crude oil, natural gas or coal. Suitable waste
management is another important aspect of sustainable development.
Plastic wastes represent a considerable part of municipal wastes;
furthermore huge amounts of plastic waste arise as a by-product or
defective product in industry and agriculture Recycling is a method of
reducing the quantity of net discards of municipal solid waste by
recapturing selected items for additional productive uses. Incineration has
become an increasingly attractive disposal option for many communities,
especially those facing dwindling landfill capacity and rapidly increasing
tipping fees, but incineration at present limits the potential of waste
plastic to energy technologies as it produce green house gases and some
highly toxic pollutants such as polychlorinated dibenzo para dioxins and
polychlorinated dibenzo furans. Thermal cracking as a waste
management option implies the decomposition of waste plastics by
using some sort of heat sources. Because, plastics are composed of
hydrocarbon originally, up on pyrolysis they are converted into fuel
oil and some other important gases and this is the best method of
utilizing waste plastics.

1
1.2.The Aim of Project is :

1) To reduce the large amount of plastic waste (method of

renewable energy).

2) To choose the suitable raw material for this process.

3) Using pyrolysis to produce the fuel oil from different types of

plastic's materials.

4) To find the optimum temperature for the production of plastic

waste from different plastic.

5) To find the optimum recovery % from different weights of raw

material.

6) Find the time of this batch process .

2
Chapter Two
Theory of Project and Literature Survey

Uncontrolled disposal of waste plastics in to the environment is becoming

undesirable due to population increase, increased use of polymeric
materials for packaging and other purposes, rising costs and the
extremely poor biodegradability of commonly used polymers. There is
therefore a need for effective plastic waste management techniques that
will convert these discarded polymer waste products to economically
useful and environmentally friendly by-products.[1] thermal conversion
of plastic waste to liquid fuel is one of chemical methods of plastic
recycling.

2.1-Plastics :

As a brief introduction to plastics, it can be said that plastics are[2]

synthetic organic materials produced by polymerization. They are
typically of high molecular mass, and may contain other substances
besides polymers to improve performance and/or reduce costs. These
polymers can be molded or extruded into desired shapes. There are two
main types of plastics: thermoplastics and thermosetting polymers.
Thermoplastics can repeatedly soften and melt if enough heat is
applied and hardened on cooling, so that they can be made into new
plastics products. Examples are polyethylene, polystyrene and polyvinyl
chloride, among others.
Thermosets or thermosettings can melt and take shape only once. They
are not suitable for repeated heat treatments; therefore after they have
solidified, they stay solid. Examples are phenol formaldehyde and urea
formaldehyde. Waste plastics are one of the most promising resources for
fuel production because of its high heat of combustion and due to the
increasing availability in local communities.

Unlike paper and wood, plastics do not absorb much moisture and the
water content of plastics is far lower than the water content of biomass
such as crops and kitchen wastes.

3
The conversion methods of waste plastics into fuel depend on the types of
plastics to be targeted and the properties of other wastes that might be
used in the process.

2.1.1- poly(methylene) is the most common plastic. The annual

global production is around 80 million tonnes. [3] Its primary use is in
packaging (plastic bags, plastic films, geo-membranes, containers
including bottles, etc.). Many kinds of polyethylene are known, with most
having the chemical formula (C2H4)n . Thus, PE is usually a mixture of
similar polymers of ethylene with various values of n.

Fig 2,1 polyethylene .

4
Fig 2,2 polyethylene properties .

2.1.2-Properties of polyethylene :
1)Mechanical properties :
Polyethylene is of low strength, hardness and rigidity, but has a high
ductility and impact strength as well as low friction. It shows strong creep
under persistent force, which can be reduced by addition of short fibers. It
feels waxy when touched.

2)Thermal properties :
The usefulness of polyethylene is limited by its softening point of 80 C
(176 F) (HDPE, types of low crystalline softens earlier). For common
commercial grades of medium- and high-density polyethylene the melting
point is typically in the range 120 to 180 C (248 to 356 F). The melting
point for average, commercial, low-density polyethylene is typically 105
to 115 C (221 to 239 F). These temperatures varies strongly with the
type of polyethylene.
5
3) Chemical properties :
Polyethylene consists of nonpolar, saturated, high molecular weight
hydrocarbons. Therefore, its chemical behavior is similar to paraffin. The
individual macromolecules are not covalently linked. Because of their
symmetric molecular structure, they tend to crystallize; overall
polyethylene is partially crystalline. Higher crystallinity increase density
and mechanical and chemical stability. Most LDPE, MDPE, and HDPE
grades have excellent chemical resistance, meaning they are not attacked
by strong acids or strong bases, and are resistant to gentle oxidants and
reducing agents. Crystalline samples do not dissolve at room temperature.
Polyethylene (other than cross-linked polyethylene) usually can be
dissolved at elevated temperatures in aromatic hydrocarbons such as
toluene or xylene, or in chlorinated solvents such as trichloroethane or
trichlorobenzene. Polyethylene absorbs almost no water. The gas and
water vapor permeability (only polar gases) is lower than for most
plastics; oxygen, carbon dioxide and flavorings on the other hand can
pass it easily.PE can become brittle when exposed to sunlight, carbon
black is usually used as a UV stabilizer.Polyethylene burns slowly with a
blue flame having a yellow tip and gives off an odour of paraffin (similar
to candle flame). The material continues burning on removal of the flame
source and produces a drip .Polyethylene can not be imprinted or stuck
together without pretreatment.

2.2-Three Main Types of Polyethylene :

By making polyethylene more or less "dense in the factory, there is a

suitable type of material available for every application. In practice one of
the following types is used in 90% of the applications.

2.2.1-LDPE:

The oldest type. A soft, tough and flexible polyethylene type, used for
strong, flexible consumer items, like screw caps and lids. For a long time
already, it is also used as insulation material. At present the most popular
application is foil, from which carrier bags, packaging material and
agricultural plastic are made. During the high water levels in Holland in
the last years, the tough strong LDPE foil served as an improvised
reinforcement for the dikes.

6
2.2.2-HDPE:

This is the sturdiest and most inflexible type. Its sturdy and somewhat
tough character can be used for a large range of applications. For example
the well-known gft-container and a number of everyday domestic
products like bottles, clothes pegs and the handle of a washing-up brush.
Although HDPE is quite heavy, it can also be used for paper-thin foil that
is extremely light and feels crispy. All of us use this type of foil daily;
examples are sandwich bags, pedal bin bags or packaging for vegetables,
fruit or meats.

2.2.3-LLDPE:

a mixture of both previous-mentioned types With this polyethylene one

can go into every direction. It has some features from both of the
previous-mentioned types. Both flexible and sturdy products are made
from it. LLDPE is generally used in mixtures with one of the previously
mentioned materials. Amongst others, even thinner foils can be produced.
It is also used for multi-layer packaging. LLDPE is extremely tough and
inflexible. These features can be used for the production of larger items,
like covers, storage bins and some types of containers.

Poly(ethene) is produced in three main forms: [4] low density (LDPE) (<
0.930 g cm-3) and linear low density ( LLDPE) (ca 0.915-0.940 g cm-3)
and high density (HDPE) (ca 0.940-0.965 g cm-3). The LDPE or LLDPE
form is preferred for film packaging and for electrical insulation. HDPE
is blow-moulded to make containers for household chemicals such as
washing-up liquids and drums for industrial packaging. It is also extruded
as piping.

2.3-Manufacture of poly(ethene) (polyethylene) :

Poly(ethene) is made by several methods by addition polymerization
of ethene, which is principally produced by the cracking of ethane and
propane, naphtha and gas oil. A new plant is being constructed in
Brazil for the production of poly(ethene), from ethene, that is made
from sugar cane via bioethanol.

7
2.3.1-Low Density Poly(Ethene) (LDPE) :

The process is operated under very high pressure (1000-3000 atm) at

moderate temperatures (420-570 K) as may be predicted from the
reaction equation:

This is a radical polymerization process and an initiator, such as a

small amount of oxygen, and/or an organic peroxide is used.
Ethene (purity in excess of 99.9%) is compressed and passed into a
reactor together with the initiator. The molten poly(ethene) is removed,
extruded and cut into granules. Unreacted ethene is recycled. The
average polymer molecule contains 4000-40 000 carbon atoms, with
many short branches.
For example,

It can be represented by:

8
Fig 2,3 structure of polyethylene.

There are about 20 branches per 1000 carbon atoms. The relative
molecular mass, and the branching, influence the physical properties of
LDPE. The branching affects the degree of crystallinity which in turn
affects the density of the material. LDPE is generally amorphous and
transparent with about 50% crystallinity. The branches prevent the
molecules fitting closely together and so it has low density.

2.3.2-High Density poly(ethene) (HDPE):

Two types of catalyst are used principally in the manufacture of HDPE:

1. a Ziegler-Natta organometallic catalyst (titanium compounds with

an aluminium alkyl).
2. an inorganic compound, known as a Phillips-type catalyst. A well-
known example is chromium(VI) oxide on silica, which is prepared
by roasting a chromium(III) compound at ca 1000 K in oxygen and
then storing prior to use, under nitrogen.

HDPE is produced by three types of process. All operate at relatively low

pressures (10-80 atm) in the presence of a Ziegler-Natta or inorganic
catalyst. Typical temperatures range between 350-420 K. In all three
processes hydrogen is mixed with the ethene to control the chain length
of the polymer.

Why we chose plastic for fuel oil production ?

The important reason to choose plastic in this process (production of fuel
oil) is : The plastic is polymers like polyethylene (PE) which is composed

9
of a chain of monomers thats produces by polymerization of ethylene
C2H4 thats produced mainly from CDU unit as refinery gases
(petroleum refinery process) and thermal cracking units. So we can
reverse this process to convert the polymer to hydrocarbon (liquid fuel oil
and gases) by applying the suitable heating amount or suitable
temperature of thermolysis of plastic.

2.4-The Processing of Waste Plastics to Produce Fuel

&Feedstock Recycling:

Feedstock recycling of plastics is a term that embraces a number [5] of

different process types. In essence, they involve reprocessing of the
material into a valuable feedstock, the end use of which is not necessarily
to produce the polymer from which it originates. The product may also be
used to produce liquid fuel. There are numerous processes for converting
waste plastics into such feedstock. Commonly known examples operate
at high volumes and generally would be integrated in existing
petrochemical or other processing complexes . These processes can
sometimes become true chemical recycling systems when integrated with
plastic manufacturing facilities. There are also examples of technologies
that form smaller capacity stand-alone developments, under normal
circumstances these will not have facilities for refining or for marketing a
wide range of products and must aim to manufacture a narrow range of
products that have high value or a ready local demand .The most common
target feed material comprises polyolefins with some tolerance for the
presence of other polymers. Due to the nature of these materials the most
convenient products with widespread and local market value are fuel for
heating or transport. Examples of such lower scale technologies have
been examined regarding their capability and outline commercial
viability. They convert waste plastics into diesel fuel.

2.4.1-Typical Processes :

Commercial confidentiality prevents detailed revelation of the process

details. However, the generic process can be described. The waste plastic
is prepared prior to supply to the process so as to remove as much
contamination and non-target plastics as required. The material is fed in a
dry state to a reactor where it is heated in the absence of oxygen. Above a
certain temperature the chemical stability of the polymer is no longer
maintained and the polymer chain begins to crack (cracking is a term
applied to this phenomenon). The break up of the chain can be to a wide

10
variety of fragment sizes meaning that a mixture of product chemicals
results. Catalysts are used by some processes to tailor the resultant
chemical species that is, by, confining the materials formed to a
narrower range. Even where catalysts are employed the conversion to
desired product will not be complete. The more specific processes aiming
at diesel production typically convert just over 80% of the incoming
plastic to this fuel. The remainder of the product will be nontarget
materials such as lighter petroleum gases, gasoline etc. A residue is
formed by material that cannot be converted to vapour. Materials not
found in the product stream will comprise other process residues
including fillers used in the original plastics and any contamination that
entered with the feedstock. Disposal of this will be necessary but it will
be a small fraction of the original plastic waste. Due to the thermal nature
of the method, process heat is required for the initial cracking stage and
for the separation of products - this can be provided directly from the
products and by-products. The equipment required for each system is
suitable for exploitation on a small scale with moderate inventories of
raw material and diesel product. There are examples of exploitation that
indicate their technical viability.

Fig 2,4 illustrates a typical process; a description of each process stage is presented
below.

11
2.4.2-Material preparation :

In some cases material may be received that is of a composition and in

a form suitable for direct addition to the cracking reactor. If this is the
case the initial feed preparation would not be necessary. Normally this
would not be the case and it will be prudent to include a material
preparation step. The design of this will be based on the range of material
mixes anticipated. The chief purpose will be to reduce contamination to
an acceptable level and put the supply to the reactor in a suitable form.
For example, the stage may wash the feed material, remove PVC plus any
included soil and stones and then shred to a form that is appropriate for
the reactor feed system.

2.4.3-Feed to process :

there are a number of options for delivery materials to the reactor,this is

an important step because the reaction must occur in the absence of
oxygen and good heat transfer properties will be desirable.

2.4.4-Thermal cracking reactor :

this is the vessel within which the plastic is heated to the necessary
temperature for the reaction to occur. As discussed above this is
conducted in the absence of oxygen, which would otherwise influence the
reaction products and present a fire hazard. There is only one exit for
desired products and that is as a vapour exiting the vapour space in the
reactor. Other materials remaining in the reactor will be residues and will
be continuously or periodically extracted. The product vapours pass
overhead to a separation train where they will be refined. Some
processing of reactor residues may be possible dependent on the details of
the individual process.

2.4.5-Separation train

the vapours exiting the reactor are mixed hydrocarbons varying from
heavy and diesel oils through gasoline to petroleum gases - many of the
components canbe selectively condensed by controlled cooling. At its

12
most sophisticated this separation train will comprise a distillation system
employing heating and cooling to enable well defined separations.
Heavier vapours will condense first and some may not be readily
condensed at all, these lighter materials will be product gases. It is
control of this stage that will determine the blend of materials making up
each reactor product. The gases remain an overhead product and have
fuel value for heating or electrical generation.

2.4.6-Liquid products :

The performance of the reaction will determine the relative

quantities of the different products exiting the reactor as vapour. Once
condensed,liquid products can be easily stored to await on site use or
distribution. The separation train will direct the liquid products to
separate storage as appropriate. Typical liquid product categories would
be fuel oil, diesel oil and gasoline. The objective is to produce the
maximum quantity of the target product.

2.4.7-Utility requirements :

Utilities are the services used by the facility and will include
electricity and water. The reactor has a heating requirement as will most
separation systems. Further requirements may be dictated by the approach
taken for the preparation stage.

2.4.8-Example Processes :

Marketed by Ozmotech the Thermalysis process has three examples of

implementation,in Japan, orders for installations are claimed for several
locations in Australia and one in Spain. The PO Process which was
developed and is marketed by Smuda Technologies Inc. has relatively
large reference plants in Poland and several smaller scale units in South
Korea, an installation is also currently under construction in Hanford, CA
in the United States. The latter process makes a further claim that
vegetable oils can also be converted to diesel. Both can process waste or
off-specification mineral oil.

13
2.4.9-Process Economics:

The economics of such processes can be strongly distorted by local

environmental practices and legal instruments. It is therefore important to
be cautious about transferring technology to the European or UK
commercial environment simply because it may be commercially
successful elsewhere. Local attitudes to the techniques, taxes,duties and
financial instruments to encourage recycling can contribute to enhance or
diminish the commercial viability. Recent increases in crude oil prices
have tended to make these developments more attractive.

The economics are best assessed by estimating the overall price of

production for a unit of product. In this case a cost per litre of diesel is a
convenient measure. The price should be built up from contributions from
all relevant costs incurred including;

- The capital cost of the plant and equipment including engineering

and

- construction

- The cost of plant commissioning

- Staffing costs and overheads

- Cost of raw materials and additives etc

- Utility costs including heat, power, lighting, water and fuel

- Maintenance costs

- Overhead costs such as rental, rates, licences to operate etc.

The first two cost types are generally referred to as capital costs and need
to be spreadover the operating life of the facility either via suitable write
off period or an interest payment approach. These are then added to the
other operating costs. When compared with a realistic sale price the
economic justification for establishing such a facility can be assessed. In
examining the economic justification for any planned facility it is also
important to make allowance for the funds necessary to prepare feasibility
14
studies etc since these sums are at risk should the project be abandoned.
Figures derived in this way may appear attractive when compared with
fuel pump prices as there is a significant tax content in the price paid by
the final consumer. It is important to understand the method of
application of this taxation to ensure that a fair comparison is made with
other sources of fuel. In the UK the manufacture of diesel fuel (and other
fuel types) is subject to excise duty.

Hence a duty becomes payable to HM Customs and Excise when the fuel
is manufactured (rather than when it is sold or transferred). The producer
needs to recover the cost of production and this excise duty when the fuel
is sold. VAT will also be charged on the sale price (currently 17.5%). At
present the manufacture of diesel from renewable resources such as
vegetable oils attracts less excise duty than from traditional raw material.
The definition of materials that qualify for this lower rate is restrictive
and currently only certain processes with specific product qualities are
eligible.

Fig 2,5 Simple block diagram of converting plastic to fuel oil.

15
Fig 2,6 Experimental apparatus diagram of recycling process .

Fig 2,7 Batch industrial process of converting plastic to fuel oil.

2.4.10-Advantages of this process :

1. Efficient

2. Economic (cost effective)

3. Eco Friendly

4. High percent yield with minimum solid waste/ residue

5. No need to sort out waste plastics (except PETE and PVC) . We

use PE on project as main reactant .

16
 6. Easy to setup (modular and mobile unit)

7. fuels work with existing internal combustion engine

8. Creates jobs

9. Free/ little cost for raw materials

10. Easy to work with existing recycling and city waste facilities

11. Low investment

Fig 2,8 Industrial scale of plastic recycling.

17
Fig 2,9Plant process of plastic recycling .

18
Fig 2,10 Plant process of plastic recycling .

19
2.5-Literature survey :

1. Preliminary Study On The Conversion Of Different Waste

Plastics Into Fuel Oil by Yasabie Abatneh, Omprakash Sahu :

The objective of the work was the conversion of waste plastics

into fuel oil. Plastic wastes such as, polypropylene, low density
polyethylene, high density polyethylene, polystyrene are the most
frequently used in everyday activities and disposed of to the
environment after service. Plastic are those substances which can
take long periods of time to decompose if disposed off simply to
the environment. Therefore, waste plastic should be changed into
usable resources. The different waste plastics were thermally
cracked at different temperature and then it was tried to
measure the oil produced, the residue left after the reaction is
completed, and the gas produced. Then it is compared that
which types of plastics can yield higher amount of oil. There are a
number of methods by which plastic wastes can be managed such
as incineration, recycling, land filling, and thermal cracking. But
this work focuses on thermal cracking of waste plastic to change
them into usable resources, because in this method the emission of
hazardous gases to the environment insignificant. This means we
can change all the waste in to useful resources.

2. Obtaining Fuels from Plastic Waste by 1Rima Ingle,2Rahul

Masal, 3Atul Gargade

Few decades ago the art of conversion of plastic to useful fuels

was scaled but there was narrow possibility towards this. Plastic
contains large majority of organic polymers which are made up of
carbon and other elements. It is made up of large link of repeat
units. Various processes like gasification, pyrolysis can be used to
convert plastic which is longer hydrocarbon into smaller units
of hydrocarbon like naphtha, diesel etc. This paper targets to
provide best possible options available which would help in
decreasing price of fuel in future.

20
 3. PYROLYSIS OF HIGH DENSITY POLYETHYLENE
(HDPE) WASTE PRODUCTS INTO USEFUL FUELS by
Abdulkareem S. A. 1 and Eleburuike N. A. 2+

High density polyethylene, HDPE was pyrolyzed in a self-designed

stainless steel laboratory reactor to produce useful fuel products. HDPE
waste (discarded yoghurt bottles) was completely pyrolyzed at 430-
5200C for 21/2 hours, to obtain solid residue, liquid fuel oil, and
flammable gaseous hydrocarbon products. Presently, due to technical
limitation, the gaseous products (lower hydrocarbons, (C1 C4) were
eluted without collection. The resulting liquid product was analyzed by
gas chromatographic-mass spectrometric (GC-MS) analysis. The GC-MS
analysis result showed that the liquid product contained hydrocarbons in
the range of C8-C24 which were all distributed between paraffinic and
olefinic hydrocarbons. The most abundant compounds in the liquid
product are the C16 C25 hydrocarbons which falls within the diesel
(gas oil) range.

4. RECOVERY OF HYDROCARBON LIQUID FROM

WASTE HIGH DENSITY POLYETHYLENE BY
THERMAL PYROLYSIS by Sachin Kumar* and R. K. Singh

Thermal degradation of waste plastics in an inert atmosphere has been

regarded as a productive method, because this process can convert waste
plastics into hydrocarbons that can be used either as fuels or as a source
of chemicals. In this work, waste high-density polyethylene (HDPE)
plastic was chosen as the material for pyrolysis. A simple pyrolysis
reactor system has been used to pyrolyse waste HDPE with the objective
of optimizing the liquid product yield at a temperature range of 400C to
550C. Results of pyrolysis experiments showed that, at a temperature of
450C and below, the major product of the pyrolysis was oily liquid
which became a viscous liquid or waxy solid at temperatures above
475C. The yield of the liquid fraction obtained increased with the
residence time for waste HDPE. The liquid fractions obtained were
analyzed for composition using FTIR and GC-MS. The physical
properties of the pyrolytic oil show the presence of a mixture of different
fuel fractions such as gasoline, kerosene and diesel in the oil.

21
 5.CONVERSION OF LDPE PLASTIC WASTE INTO LIQUID
FUEL BY THERMAL DEGRADATION By 1GAURAV,
2MADHUKAR M, 3ARUNKUMAR K.N., 4N S LINGEGOWDA

Plastics have woven their way into our daily lives and now pose a
tremendous threat to the environment. Over a 100 million tonnes of
plastics are produced annually worldwide, and the used products have
become a common feature at overflowing bins and landfills. Though
work has been done to make futuristic biodegradable plastics, there have
not been many conclusive steps towards cleaning up the existing
problem. Here, the process of converting waste plastic into value added
fuels is explained as a viable solution for recycling of plastics. Thus two
universal problems such as problems of waste plastic and problems of
fuel shortage are being tackled simultaneously. In this study, plastic
wastes (low density polyethylene) were used for the pyrolysis to get fuel
oil that has the same physical properties as the fuels like petrol, diesel etc.
Pyrolysis runs without oxygen and in high temperature of about 300C
which is why a reactor was fabricated to provide the required temperature
for the reaction. The waste plastics were subjected to depolymerisation,
pyrolysis, thermal cracking and distillation to obtain different value added
fuels such as petrol, kerosene, and diesel, lube oil etc. Converting waste
plastics into fuel hold great promise for both the environmental and
economic scenarios. Thus, the process of converting plastics to fuel has
now turned the problems into an opportunity to make wealth from waste.

6.Pyrolysis of High-density Polyethylene for the Production of

Fuel-like Liquid Hydrocarbon by Ammar S. Abbas* and Sawsan D.
A. Shubar

pyrolysis of high density polyethylene (HDPE) was carried out in

a 750 cm3 stainless steel autoclave reactor, with temperature
ranging from 470 to 495 C and reaction times up to 90 minute.
The influence of the operating conditions on the component yields
was studied. It was found that the optimum cracking condition
for HDPE that maximized the oil yield to 70 wt. % was 480C
and 20 minutes. The results show that for higher cracking
temperature, and longer reaction times there was higher
production of gas and coke. Furthermore, higher temperature
increases the aromatics and produce lighter oil with lower
viscosity.

22
Chapter three
Experimental Work

As we mentioned at chapter two about plastic types .. i.e polyethylene,

There are many different plastic types and they have specific properties
that influence their end uses when recycled and the means by which they
can be reprocessed. Some processes can tolerate a certain amount of
contamination by non-target plastics but a specification will always need
to be met for successful operation. The feedstock recycling process used
must be suitable for the types of plastic targeted. The investigation was
initiated to examine the viability of the processes in handling agricultural
plastic waste. Although relatively high levels of contamination are often
expected of such waste, the plastic types used for agricultural applications
tend to conform to a conveniently suitable group. Contamination of the
waste by non-plasticmaterial can be removed, in principle, by a feed
preparation stage. Most agricultural plastics conform to the polyolefin
group of polymers. We used HDPE and plastic waste (detergent bottles) ,
LDPE and PPE need vacuum pressure for experiment runs , so we did not
use both , PVC should be avoided due to its chlorine content with
deleterious consequences to the equipment materials of construction
and the quality of diesel that would be produced. The presence of
small amounts has normally been considered by the technology
developers and front end or in-process removal systems proposed.

We can recognize the PVC and other types of plastic by thermal

properties .. PVC is thermal setting and the Polyethylene is thermo
plastic.

3.1-Apparatus :
1) Pyrolysis reactor :cylindrical rector of carbon steel (2 inch diameter
and 12 cm height) which was jacketed with 1.5 kw heater
surrounded with thermal isolation for energy conversation.
2) The reactor was connected with thermo couple of J type which was
connected to (on-off) thermal controller.
3) The decanter of 5L volume was connected to reactor by using
copper pipe and filled by water.

3.2-Sample Collection and Preparation :

23
HDPE, particularly discarded yoghurt bottles, were obtained from
household and municipal wastes. Then, they were washed, dried and
shredded into small sizes for easy handling and faster decomposition.

3.3-Procedure of Experiments :
The equipment was installed like in fig, 3.1. the heater was operated to
generate heat of pyrolysis decomposition . the temperature was controlled
by controller. The plastic reached melting point about 130 t0 150C. at
200C light gases started to rises from reactor to decanter generating the
bubbles . At the vaporization point the vapors started to rise to decanter
making the first drop of liquid fuel on the surface of water inside decanter
. vaporization point for HDPE was 296C and 277C for the waste
plastic. The vapors was condensed by decanter forming two layers of
liquids which is water and fuel oil or liquid product we can separate
them by density difference. The gases is non-condensable by-
products, that was released to atmosphere.

We had done four experiments for our project :

1) we placed HDPE in reactor with weight of 20 g and we increased

temperature by using the controller to have the weight of product for each
temperature degree (this experiment had more than 6 runs for every run
had it's temperature degree).In our experiment we found the temperature
of maximum recovery of products was 375C.

2) we placed HDPE in reactor at 375C of different weight of raw

material for each run to obtain the weight of product for each weight of
raw material .

3) it was like first experiment but with using plastic waste discarded of
yoghurt and detergent bottles, the plastic waste was placed inside reactor
with different runs each run had it's temperature degree to obtain the
weight of product for each run.

4) the HDPE was placed in reactor at 375C and 20 g of raw material for
obtaining the weight of product of different times by using stopwatch.

24
Fig, 3,1 the configuration of the process .
25
Note that we used the decanter instead the condenser
because of the condenser rejection heat less than
decanter because of the density of water is higher than
the density of air inside the tubes of condenser, and the
mixing action of fluids during the heat exchanging is more
efficient than by unmixed action . And as recommended
on literatures the decanter separates different liquids by
mean of density difference .

3.4-Collecting the product :

the liquid product was accumulated above the water layer as liquid layer
separated by density difference. The output of decanter was closed during
and run or experiment. When we wanted to collect the liquid product, we
let the water discharged from the output stream of decanter until we
reached interfacial line between two liquids, we started to collect liquid in
collecting bottle.

26
Fig, 3.2 liquid products .

Chapter four
The Results and Discussion

We did experiments in chapter 3, we had set values of results for each

experiment, all results depended on it's condition , the operating method
and the state (composition and the quantity) of raw material.

4.1-Effect of temperature for HDPE:

For first experiment of raw material HDHE of 20g was placed in the
reactor with set points of temperature degrees to obtain the following
results :

Table 4.1 result of first experiment.

Temperat
ure wt of
product
(C) (g)

259 0
275 6.0781
295 8.0002
11.604
315 2
13.406
335 5
15.994
355 3
375 17.867

27
 14.023
395 4
415 12.023

fig 4.1 temperature vs wt of product for first experiment.

In the first experiment the weight of product increased with the

temperature degree increase until it reached at the maximum temperature
about 375C , after the maximum temperature the weight of product
decrease with the temperature increase because of wax forming from
using HDPE as raw material .

4.2-Raw material weight effect for HDPE:

The second experiment, we used raw material HDPE of different weight
with set point of 375C (maximum temperature on first experiment), we
had these results :

Table 4.2 result of second experiment.

wt of raw wt of recovery
material
(g) product(g) %

10 6.842 68.42
20 17.867
28 89.335
25 18.304 73.216
30 22.065 73.55
35 16.068 45.90857
fig 4.2 plot of results of second experiment.

In the second experiment, the maximum recovery was at 20g of raw

material (HDPE) , because of forming of a lot of wax bellow 20 g and
low heat distribution for above 20 g . this depends on the duty of heater
which was coiled around the reactor.

Note :

29
 4.3-Effect of temperature for plastic waste:
In third experiment, we used the pieces of waste plastic (detergent and
yoghurt bottles) instead HDPE on first experiment. We placed 20 g of
these plastic pieces in the reactor with different temperature degrees to
obtain the following results:

Table 4.3 results of third experiment, the weight of product vs the

temperature degrees of plastic waste .

Temperature wt of
product
(C) (g)

277 0
290 3.51
310 5.546
350 11.067
376 14.715
380 15.13
397 16.92106
400 17.09
410 8.219
430 6.106

30
Fig 4.3 plot of results of third experiment.

. In the third experiment the weight of product increased with the

temperature degree increase until it reached at the maximum temperature
about 400C , after the maximum temperature the weight of product
decrease with the temperature increase because of wax forming from
using waste plastic as raw material .

4.4-Time effect for HDPE:

The fourth experiment, we placed the 20 gm of HDPE at 375C in the

reactor by using stopwatch we obtained time vs weight of product results:

Table 4.4 the results of fourth experiment.

Time
(min) wt of
product(g
)

0 8.063
10 12.01

31
 20 15.0678
25 16.0784
26.05 16.9873

fig 4.4 the plot of results of fourth experiment.

In the fourth experiment, the maximum time of maximum recovery %

and maximum temperature 375C was 26.05 min for HDPE and the
forming of liquid fuel stopped .

32
Chapter five :
Conclusions and future works

5.1- conclusions :

1) we can convert the plastic waste to fuel oil ..

2) The LDPE is not suit for our system , because of formation of solid
parafines faster than the HDPE at atmospheric pressure , our system
needs the vacuum pressure operation to be suitable for LDPE..
3) the decanter was more efficient than the condenser because of mixed
fluid effect and the separation due to density difference.
4) the maximum product weight need the optimum heat distribution on
the reactor by using the maximum temperature for optimum weight of
plastic waste.
5) we can do the fractiation distillation for the product to obtain the light
product.
6)PVC should be avoided due to its chlorine content with deleterious
consequences to the equipment materials of construction and the quality
of diesel that would be produced. The presence of small amounts has
normally been considered by the technology developers and front end or
in-process removal systems proposed.

5.2-future works :

1) production of fuel oil by using LDPE or water bottles (polypropylene)

by employee vacuum pressure of same process.
2) conversion the gaseous and vapors products to light fuel friction by
using catalytic process.
3) using the fractional distillation to obtain the light fuel friction from
liquid product of our process (pyrolysis liquid product of HDPE or
LDPE).
4) fuel oil production by using rubber and resins wastes.

33
References :

1- PYROLYSIS OF HIGH DENSITY POLYETHYLENE (HDPE)

WASTE PRODUCTSINTO USEFUL FUELS Abdulkareem S.
A.1and Eleburuike N. A. 2+ .

2- Converting Waste Plastics into a Resource Compendium of

Technologies, United Nations Environmental Programme
Division of Technology, Industry and Economics International
Environmental Technology Centre Osaka/Shiga, Japan.

3- en.wikipedia.org/wiki/Polyethylene .

4- www.essentialchemicalindustry.org/polymers/polyethene.html .

5- Plastics Technical Briefing Note Stand Alone Facilities for

the Conversion of Waste Plastics to Diesel Fuel by Remade
Scotland .

34