Dr. Achyut Kumar Panda Plastics to Fuel by Dr... · My work at NIT Rourkela Publications References. Waste plastic to fuel-A sustainable approach to energy recovery Dr. Achyut K.

WASTE PLASTICS TO FUEL:

A SUSTAINABLE METHOD FOR WASTE REDUCTION AND

ENERGY GENERATION

By

Waste plastic to fuel-A sustainable approach to energy recoveryDr. Achyut K. Panda

Department of Chemistry1

Dr. Achyut Kumar Panda

Dept. of Chemistry

School of Engg and Technology, Parlakhemundi, CUTM Odisha

Acknowledgement

•Prof.(Dr.) R.K.Singh, Professor, Dept of Chemical

Engg.NITR and PhD Guide

•Dr. Dhanada Kanta Mishra, PhD Co-guide

•Prof.(Dr.) Mukti Mishra, President, CUTM

•Prof. D.N.Rao, Vice president, CUTM

•Brig.H.K.Sahu, Director, QA, CUTM



•Brig.H.K.Sahu, Director, QA, CUTM

Contents

� Introduction

� Definition of plastics, type, recyclability

� Different types of plastic waste management

� Chemical Recycling (Cracking/Pyrolysis)

� Process design



� Process design

� My work at NIT Rourkela

� Publications

� References









But NOW you may say YES to plastics

HOW???????



???????

Definition of plastics, type, recyclability

• Plastic covers a range of synthetic or semi synthetic polymerization products

which can be moulded into any desired shape when subjected to heat and

pressure.

• They composed of organic condensation or addition polymers and may

contain other substances to improve performance or economics. A finished

high-polymer article not only consists solely of high polymeric material

(polymer or resin) but is mixed with 4 to 6 ingredients, such as lubricant,

filler, plasticizer, stabilizer, catalysts, and colouring material.

• There are mainly two types of Plastics: Thermoplastics and Thermosetting



• There are mainly two types of Plastics: Thermoplastics and Thermosetting

Plastics

• Thermoplastics are those, which once shaped or formed, can be softened by

the application of heat and can be reshaped repeatedly, till it looses its

property. Example: Polyethylene, Polypropylene, Nylon, Polycarbonate etc.

• Thermosetting Plastics are those, which once shaped or formed, cannot be

softened by the application of heat. Excess heat will char the material.

Example: Phenol formaldehyde, Urea Formaldehyde, Melamine

Formaldehyde, Thermosetting Polyester etc.

�Plastics are "one of the greatest innovations of themillennium"

Why Plastics?�The fact that plastic is lightweight, does not rust or rot, lowcost, reusable/recyclable.

�Again, Plastics save energy and CO emissions during their

It’s Plastic Age…….



�Again, Plastics save energy and CO2 emissions during theiruse phase. If we were to substitute all plastics in all applicationswith the prevailing mix of alternative materials, and look from alife cycle perspective, then 22.4 million additional tons of crudeoil per year would be required.

Mark

Type

Recyclable

Abbreviation

Description & Common uses

Type 1

Yes PET Polyethylene Terephthalate Beverages.

Type 2

Yes HDPE High-Density Polyethylene Milk, detergent & oil bottles, toys, containers used outside, parts and plastic bags.

Type 3

Yes, But not common

PVC Vinyl/Polyvinyl Chloride Food wrap, vegetable oil bottles, blister packages or automotive parts.



not common packages or automotive parts.

Type 4

Yes LDPE Low Density Polyethylene, Many plastic bags, shrink-wraps, garment bags or containers.

Type 5

Yes PP Poly Propylene. Refrigerated containers, some bags, most bottle tops, some carpets, and some food wrap.

Type 6

Yes, but not common

PS Polystyrenes. Through away utensils, meatpacking, protective packing.

Type 7

Some ------------

Other. Usually layered or mixed plastic.

Origin of the problem

� Scarcity of fossil fuel:

� Fossil fuels (petrolium, natural gas, coal) are the major sources of energy.

� International Energy Outlook 2010 reports the world consumption of petroleumoil as 84 million barrels per day and that of natural gas as 19 million barrels oilequivalent per day. This way, the oil and gas reserve available can meet only 43and 167 years further.

� Mankind has to rely on the alternate/renewable energy sources like biomass,



� Mankind has to rely on the alternate/renewable energy sources like biomass,hydropower, geothermal energy, wind energy, solar energy, nuclear energy etc.

� Waste Plastic to fuel can be a substitute for fossil fuel.

� Solid waste management:

� Plastic in municipal solid waste streams make up only 7-9% of the weight of the total waste stream, by volume they may represent 20-30%.

� Plastics waste can be managed in a greener way by this technique.

STATISTICS OF PRODUCTION OF PLASTICS

� The total global production of plastics has grown from around 1.3 milliontonnes (MT) in 1950 to 245MT in 2006.

� The highest consumption of plastics among different countries is found in USAwhich is equal to 27.3MT against 170MT world consumption in 2000 and isexpected to reach to 39MT by 2010.

� The growth of the Indian plastic industry has been phenomenal equal to17% ishigher than for the plastic industry elsewhere in the world.

� India had a plastic consumption of 3.2MT during 2000 and has reached nearly



� India had a plastic consumption of 3.2MT during 2000 and has reached nearly12.5 MT by 2010. Hindu Business line, Jan 21, 2006 reveals India will be thethird largest plastics consumer by 2010 after USA and china.

Plastic consumption

Per capita consumption of plastics in (kg/year)

60

80

100

120

140

160

kg/year

1980

2000

2010



0

20

40

60

Wor

ld

Asi

a

Afri

ca

Wes

tern

Eur

ope

Eas

tern

Eur

ope

USA

Japa

n

Chi

na

Indi

a

Place

2010

Country wise Plastic consumption in MT

202530354045

MT of plastics

2000

2010

Plastic consumption



05

101520

USA

China

Indi

aJa

pan

Ger

man

yS.K

orea

Italy

Brazi

lFra

nce

UK

Country

MT of plastics

2010

CONTD………

STATISTICS OF GENERATION OF PLASTICS WASTES

� The rapid rate of plastic consumption through out the world has led to the creation ofincreasing amounts of waste. Plastics have become a major threat due to their non-biodegradability and high visibility in the waste stream. Littering also results insecondary problems such as clogging of drains and animal health problems.

� The amount of plastic wastes in Europe was 30 MT during 2000 and it will reach 35 MT by 2010.

� In USA the amount of plastic waste was 24.8MT in 2000 and 29.7MT in 2006. The amount of plastic consumed as a percentage of total waste has increased from less than 1



amount of plastic consumed as a percentage of total waste has increased from less than 1 percent in 1960 to 11.7 percent in 2006.

� In Japan, 15MT of plastics are produced annually and 10 million tons of plastics are discarded.

� Similarly in India the amount of plastic waste during 2000/01 was 2380kT and is estimated to more than 5000kT by 2010.

Sources and properties of plastic wastes

� Plastic wastes can be classified as industrial and municipal plastic wastes

according to their origin. Industrial plastics wastes are homogeneous and that of

municipal plastic wastes are heterogeneous.

� Industrial plastic wastes are those arising from the large plastics manufacturing,

processing and packaging industry. The industrial waste plastic mainly

constitute plastics from construction and demolition companies electrical and

electronics industries , by-product or faulty product in industry and agriculture

and the automotive industries spare-parts.



and the automotive industries spare-parts.

� Municipal plastic wastes (MSW) normally remain a part of municipal solidwastes as they are discarded and collected as household wastes. Plastic inmunicipal solid waste streams make up only 7-9% of the weight of the totalwaste stream, by volume they may represent 20-30%. Of the organic wastestream, that is, after removal of glass, metals, etc., plastics are about 9-12% byweight

CONTD…….

� Of the total plastic waste, over 78 wt. % of this total corresponds to thermoplastics(mainly polyolefins, LDPE-17%, HDPE-11%, PP- 16%) and the remaining to thermosets(mainly epoxy resins and polyurethanes).

� More than 70% of the thermoplastics are composed of polyolefins such as polyethylene(PE), polypropylene (PP), polystyrene (PS) and polyvinyl chloride (PVC).

� The thermosets which include materials such as polyamides, polyesters, nylons andpolyethylene terephthalate can be depolymerised via reversible synthesis reactions toinitial diacids and diols or diamines. Typical depolymerisation reactions such asalcoholysis, glycolysis and hydrolysis yield high conversion to their raw monomers.



alcoholysis, glycolysis and hydrolysis yield high conversion to their raw monomers.

� Thermoplastics which include materials such as polyolefins, typically making up 60–70% of municipal solid waste plastics, cannot be easily depolymerised into the originalmonomers by reverse synthesis reaction. However, they can be depolymerised tomonomer or fuel like product by different thermolysis process (Hydro cracking, thermalcracking, catalytic cracking).

Different methods of plastic waste management



Suitability of Chemical recycling

� Land filling (shortage of land, Rising cost of land, increased legislation)

� Mechanical recycling (High energy process, low quality of secondary product)

� Biological recycling (applicable for biodegradable plastics)

� Chemical recycling by Pyrolysis (Produce fuel & monomer). Use of waste



� Chemical recycling by Pyrolysis (Produce fuel & monomer). Use of waste

plastics, cheap and reusable catalyst, no emission, thus a green method of waste

management.

CONTD…….

� During early 2000, the largest amount of plastic wastes is disposed of by land

filling (65-70%), and incineration (20-25%). Recycling is only about 10%.

� In Japan, the percentage of municipal plastic wastes, as a fraction of MSW, that

was land filled in the early 1980s was estimated to be 45%, incineration was

50%, and the other 5% was subjected to separation and recycling.

� In the USA, more than 15% of the total MSW was incinerated in 1990; only

about 1% of post-consumer plastics were recycled. In India, during 1998 around

800,000 tonnes representing 60 per cent of plastic wastes generated in India was



800,000 tonnes representing 60 per cent of plastic wastes generated in India was

recycled involving 2,000 units. This level of recycling is the highest in the

world.

� The corresponding figure for Europe is 7 per cent, Japan 12 per cent, China 10

per cent, and South Africa 16 per cent.

� In Europe 2006 marks a milestone as the first year when recovery and disposal

rates of used plastic were equal. The recovery rate of post-consumer end-of-life

plastics now stands at 50% and disposal stands at 50%.

ADVANTAGES OF FEEDSTOCK RECYCLING TO FUEL

OVER OTHER PROCESS

� Solid waste management: This process would also take care of hazardous high volume plasticwaste simultaneously produce useful fuel/monomer.

� Ecological aspect: This is important today from the Global Warming point of view as it doesn'tproduce greenhouse gases and the operator in a developing country would be able to cash on theCarbon Credit.

� Easy feed stock: Whereas Mechanical Recycling requires homogeneous, clean and dry waste beforeprocessing stage (mostly extrusion), complicated mixtures of plastics waste can be recovered byFeedstock Recycling without problem as long as the waste can be mechanically fed to the systemand the waste is free from some contamination / hazardous substances, to avoid complications inspecific systems.



specific systems.

� Cost: The cost of Feedstock Recycling even in the best case of large-scale plants may be similar (ashigh as) to the cost for incineration and energy recovery.

� Substitute of fossil fuel-A renewable source of energy: The current statistics (for year 2007-08) ofcrude oil consumption in India is 115 million MT per annum, 75-80 percent of which has to beimported at the rate of average $100 per barrel 2008 ($140 up to sept.2008 and $ 70 after sept.2008)and that one liter of crude oil yields only 600 ml of hydrocarbon fuel. A suitable process which canconvert waste plastic to hydrocarbon fuel if designed and implemented then that would be a cheaperpartial substitute of the petroleum without emitting any pollutants. The consumption of petroleumproduct would decrease. It reduce the import of crude oil.

Calorific values of plastics compared with conventional fuels

Calorific values of plastics compared with conventional fuels

Fuel Calorific value (MJ/kg)

Methane 53

Gasoline 46



Fuel oil 43

Coal 30

Polyethylene 43

Mixed plastics 30-40

Municipal solid waste 10

Thermolysis/Cracking/pyrolysis

� Cracking processes break down polymer chains into useful lower molecular weightcompounds at high temperature in absence or limited supply of oxygen. Three differentcracking processes such as hydrocracking, thermal cracking and catalytic cracking arereported.

� Hydrocracking of polymer waste typically involves reaction with hydrogen over acatalyst in a stirred batch autoclave at moderate temperatures and pressures to yieldgasoline range products.



� Thermal cracking, or Pyrolysis, involves the degradation of the polymeric materials byheating in the absence of oxygen at a temperatures between 500 - 800ºC and results in theformation of a carbonized char (solid residues) and a volatile fraction that may beseparated into condensable hydrocarbon oil consisting of paraffins, isoparaffins, olefins,naphthenes and aromatics, and a non-condensable high calorific value gas.

� Catalytic pyrolysis involves the degradation in presence of a suitable catalyst

Advantages of Catalytic Cracking

� Significantly lowers pyrolysis temperatures and time. Results in an increase in the

conversion rates for a wide range of polymers at much lower temperatures than with

thermal pyrolysis.

� Narrows and provides better control over the hydrocarbon products distribution

While thermal pyrolysis, results in a broad range of hydrocarbons ranging from C5 to C28,

the selectivity of products in the gasoline range (C5-C12) are much more enhanced by the

presence of catalysts. Again, oils obtained by catalytic pyrolysis contain less olefins and



presence of catalysts. Again, oils obtained by catalytic pyrolysis contain less olefins and

more branched hydrocarbon and aromatic content.

Process Design

�Feed Composition (Type of Polymer) on Product yield and

distribution: Study of pyrolysis of different plastics individually and together

�Catalyst loading: Study using different catalysts

�Catalyst Contact Mode: “liquid phase contact” and “vapor phase contact”

�Particle/Crystallite Size of Catalyst on Product Distribution:



�Particle/Crystallite Size of Catalyst on Product Distribution:

Macro/ nano sized catalyst, Use of nano catalysts are sparsely studied

�Reactor Type: Batch reactor, semi batch reactor, Continuous flow reactor,

fluidized bed reactor

�Other Process Parameters such as temperature, residence time, pressure,

presence of other gases such as O2, H2, Ar, N2 etc

CONTD…….

Sl. Number Polypropylene LDPE Polystyrene

Different researchers R. C. Mordi et al. 1994

W. Zhao et al. 1996

Y. Sakata et al. 1996

J. Aguado et al. 1997

M. A. Uddin et al. 1997

Y. H. Lin et al. 1998

Y. Ishihara et al. 1989

C. Salvador et al. 2000

De la Puente G et al.1989

Ishihara Y et al. 1990

M. A. Uddin et al. 1997

Zhou Q et al. 2003

Shah J et al. 2005

A. Aboulkas et al.2006

J. Aguado et al. 2009

C. Covarrubias et al. 2010

S. Sato et al. 1990 G.

Audisio et al. 1990

D.P. Serrano et al. 2000

Y. Liu et al. 2000

H. Ukei et al. 2000

A. Karaduman et al. 2001

Aguado J et al. 2001S.Y. Lee

et al. 2001



C. Salvador et al. 2000

J. R. Kim et al. 2002

A. Marcilla et al. 2003

W. Zhao et al.2004

A. Durmus et al. 2005

Jose´ M et al. 2008

Y. H. Lin et al. 2005

S. H. Jung et al. 2010

Hyun Ju Parka et al. 2008

C. Covarrubias et al. 2010

D.P. Serrano et al. 2010

Y S González et al.2011

et al. 2001

R. Aguado et al. 2003

C.G. Lee et al. 2003

R.S. Chauhan et al. 2008

CONTD……


Type of catalysts Used BEA, ZSM-5 and Mordenite,

acid treated clinoptilolite

zeolites, H-Y zeolites, Na-Y

zeolites, H-mordenite, Na-

mordenite, silica–alumina and

H-ZSM-5, Al2O3, SiO2, REY

zeolites, MCM-41, H-USY

zeolites, non-acidic

mesoporous silica catalyst

MoO3 (5%wt%) mixed silica

(95wt.%), ZSM-5, desilicated

ZSM-5 (DeZSM-5) and

lanthanum incorporated

LaZSM-5, lead sulfide, Fly

ash-derived amorphous silica–

alumina catalysts, silica,

calcium carbide, alumina,

magnesium oxide, zinc oxide

HY zeolites (Protonated Y

zeolite) or REY zeolites (Rare

earth Y zeolite), silica

alumina, HMCM-41

(Protonated MCM-41), natural

clinoptilolite, ZSM-5 (Zeolite

Sieve of Molecular porosity or

Zeolite Socony Mobil–5),

mordenite, BaO, MgO, Fe2O3



(FSM), SAHA, FCC, HY

zeolite (320HOA).

and homogeneous mixture of

silica and alumina, Silica

Alumina, HZSM-5, HY, and

H-mordenite zeolites and

silica alumina

2 3

CONTD…….


Type of reactor used semi batch reactor, catalytic

fluidised-bed reactor, fixed

bed reactor

Batch reactor flow reactor and

a batch reactor, Pyrex

continuous reactor, batch

reactor provided with a screw

stirrer under a continuous

nitrogen flow

Batch Reactor, fluidized bed

reactor, conical spouted bed

reactor (CSB), internally

circulating fluidized bed reactor

(ICFB), swirling fluidized bed

reactor (SFB).



Temperature Range (0C) 350-500 200-600 350-875

Major Product Gasoline range hydrocarbon Gasoline range hydrocarbon Aromatic products, major

Styrene

Mode of decomposition Random chain rupture Random chain rupture Combination of unzipping and

chain rupture, forming

oligomers

Catalysts used

� The most commonly researched solid acid catalysts in plastic waste pyrolysis

includes silica alumina, zeolites , MCM-41, clays (montmorillonite, saponite),

reforming catalysts, activated carbon, metal oxides, metal complexes of the type

MCln-AlCl3 or M(AlCl4)n (M=Li, Na, K, Mg, Ca, Ba; n=1–2), and alkali metal

carbonates or alkaline metal carbonates have also been tested for polymer

degradation.

� Amongst the numerous kinds of zeolites investigated in polyolefin pyrolysis,



� Amongst the numerous kinds of zeolites investigated in polyolefin pyrolysis,

Beta, USY, ZSM-11, REY , Mordenite , ZSM-5, are common.

� The common features shared by the different Zeolite catalysts are proper

acid strength, pore size and pore structure.

Commercialization of Process

�In the early 1990s BP Chemicals first tested technology for feedstock

recycling, using a fluid bed cracking process. Research on a laboratory scale was

followed (1994) by demonstration at a continuous pilot plant scale (nominal 50

kg/hr) at BP’s Grangemouth site, using mixed waste packaging plastics. BP

Chemicals, VALPAK and Shanks & Mc Ewan, set up a joint project (POLSCO),

to study the feasibility of a 25 000 tonne/yr plant, including logistics

infrastructure for supplying mixed plastics from Scotland.

�Veba Oil developed a commercial process, operating in a temperature range of



�Veba Oil developed a commercial process, operating in a temperature range of

350–450◦C and requiring a high hydrogen partial pressure (50–100 bar). The

technology was realized in the coal-to-oil plant at Bottrop, with a capacity of 40

000 tonne annually doubled at the end of 1995.

�A plant operating according to the Hamburg University pyrolysis process

was built at Ebenhausen, Germany with a capacity of 5000 tonnes per year.

�Ozmotech Pty Ltd, a privately owned Australian company, announces envirof

uel to market and operate thermofuel plants worldwide which converts the

thermo fuel plastics to diesel system.

�An oil refinery in Hunan province had succeeded in processing 30 000 tonnes of

plastic wastes into 20 000 tonnes of gasoline and diesel oil that satisfied the provincial

standards.

�Environmental Technology Systems Ltd is a U.K. company, incorporated in 2003,

which now has the rights to acquire a proven Chinese technology to convert waste

plastics into gasoline and diesel fuels produce 2,000 tonnes per annum of fuel oil

(roughly, half petrol and half diesel) from 2,740 tonnes of waste plastics.

�A large pilot plant, with a substantial capacity of 15 000 tonne/yr, was started up in

Ludwigshafen in 1994 by the BASF in which plastic waste is converted into

Commercialization of Process



Ludwigshafen in 1994 by the BASF in which plastic waste is converted into

petrochemical products using a tubular cracker reactor

�In India, a zero-pollution industrial process to convert non-biodegradable and

mostly non-recyclable plastic waste into liquid hydrocarbons has been set up at

Butibori industrial estate, Nagpur by Prof. Alka Zadgaonkar. The Zadgaonkar’s

Unique Waste Plastic Management & Research Company plant devours a whole

range of plastic waste.

� Enviro-Hub the waste management and recycling firm announced the construction

of Singapore's first $50 million plastic-to-fuel plant which converts waste plastic into

useable fuels and gases.

Zadgaonkar’s plastic fuel



CONTD……

Properties Regular gasoline Plastic waste fuel

Colour, visual orange Pale yellow

Specific gravity at 280C 0.7423 0.7254

Specific gravity at150C 0.7528 0.7365

Gross calorific value 11210 11262

Net calorific value 10460 10498



Net calorific value 10460 10498

API gravity 56.46 60.65

Sulphur content (by mass) 0.1 <0.002

Flash point 0C 23 22

Pour point 0C <-200C <-200C

Cloud point <-200C <-200C

Work at NIT Rourkela



The Work

•The work focused on the thermal and catalytic pyrolysis of waste plastics

[Polypropylene (PP), Low Density Polyethylene (LDPE), and Polystyrene

(PS)] to liquid fuel/chemicals using kaolin activated kaolin catalyst.

•The main objective was to screen the catalyst and optimize the process to

obtain suitable liquid fuel from different waste plastics.

•Characterization of liquid fuel for its composition and fuel properties for its



•Characterization of liquid fuel for its composition and fuel properties for its

suitability as fossil fuel substitute and study the engine performance and

emission analysis was other aspects of the work.

Materials and Methods



Materials and Methods

Collection of the plastic materials



Virgin PP Poly-bags made of

LDPE

Thermocol made of Expanded

PolystyreneDisposal glass made of PP Omfed milk

packets

Experimental set up for pyrolysis



Process of conversion of Waste Polypropylene to Fuel oil

Experimental Set up and Stainless steel Reactor

Schematic diagram of the set up



•Different catalysts such as screening of Kaolin, zeolite, silica

Alumina, Activated carbon, Modernite used in the experiment to

screen the suitable catalyst

•Acid activation Kaolin for improvement of catalytic properties.

Catalyst used and its activation



Characterization Techniques

�Characterization of Catalysts: SEM- Surface morphology

XRD- Phase analysis

TGA- Thermal analysis

BET-Surface area, pore volume distribution, pore diameter

XRF- composition

FTIR-Type of bonding

TPD- Acidity of catalyst



TPD-Acidity of catalyst

�Characterization of liquid products: FTIR for functional group, Detailed hydrocarbon analyser for composition (PIONA),

RON, MON, Br-number, IBP and FBP, flash point and fire point by Pensky Martin

flash point apparatus, specific gravity by picnometer, cloud point by pour point

apparatus, calorific value by bomb calorimeter, viscosity by Redwood viscometer.

RESULTS OF PYROLYSIS

� In polypropylene pyrolysis, the yield of oil increased by 7.3% and reaction time

decreased by 25.4% at 5000C with 1:3 catalyst to polymer ratio using kaolin as catalyst

as compared to thermal reaction . Again the yield of oil increased by 11.8% and reaction

time decreased by 32.4% at 5000C with 1:3 catalyst to polymer ratio using activated

kaolin. The maximum oil yield was 87.5% and 92% using kaolin and acid treated kaolin

respectively. Product distribution narrowed using the catalysts for e.g. in thermal reaction

there are 56 no of different components (C9-C20), where as it reduced to 36 (C10-C18) and

12 (C9-C13) no of components using kaolin and acid treated kaolin.



� In LDPE pyrolysis, the yield of oil increased by 10.6% and reaction time decreased by

63.8% at 4500C with 1:2 catalyst to polymer ratio using kaolin catalyst. The maximum

yield being 80%. Compositional analysis of the oil obtained in catalytic pyrolysis

concludes that the products mainly consisted of paraffinic and olefinic compounds (C10-

C14).

� In polystyrene pyrolysis, the liquid fraction increases from 93% to 94.5 wt. % by the

addition of kaoline clay as catalyst in the 1:10 catalyst to polymer ratio at 5000C. The

styrene content is about 65%.

Liquid Product of pyrolysis



Properties of petro fuel

Physical properties Gasoline Kerosene Diesel PP oil LDPE oil

Refractive Index 1.434 1.44 1.484 1.452 1.45

Density 0.72-0.736 0.78-0.82 0.83-0.85 0.7771 0.778

Specific gravity 0.72-0.73 0.78-0.82 0.83-0.85 0.7777 0.7794

API gravity 65.03-62.34 49.91-41.06 38.98-34.97 50.447 50.050



Viscosity 0.775-0.839 1.2-1.8 2.0-4.5

Kinematic viscosity

(Cst) @ 30OC

1.076-1.140 1.54-2.20 2.4-5.3 2.27@ 30OC 1.89@ 40oC

Flash point (0C) 38 50-55 55-60 < - 12oC -23oC

Pour point (0C) < - 45oC - 40C

Boiling point range

(0C)

40-205 175-325 150-350 39-346 40-284

Calorific value

(MJ/kg)

46.9 45.5 43.7 47.27 42.55

FUEL PROPERTIES OF THE OIL

Tests

Kaoline

catalysed oil

Parent oil

1st fraction

(<2000C)

2nd fraction

(>2000C)

Si-Al

catalysed oil

Colour Yellow Colour less Reddish Yellow

Specific Gravity@ 15OC/15oC 0.7777 0.7123 0.7982 0.7712

Density @ 15oC in gm/cc 0.7771 0.7117 0.7975 0.7702

Kinematic Viscosity in Cst@ 30OC 2.27 1.9 4.1 2.21



Kinematic Viscosity in Cst@ 30OC 2.27 1.9 4.1 2.21

Pour Point < - 45oC < - 50oC < - 45oC < - 45

Cloud Point < - 45oC < - 50oC < - 45oC < - 45

Gross calorific Value in Kcals/kg 11,256 10,809 10,096 11,262

Flash Point by Abel < - 12oC - 36oC 33oC < - 12

Fire Point < - 12oC - 34oC 40oC < - 12

Boiling point range (0C) 68-346 36-162 145-34759-341

ENGINE PERFORMANCE AND

EMISSION ANALYSIS



ENGINE PERFORMANCE AND EMISSION

ANALYSIS OF WASTE POLYPROPYLENEPLASTIC OIL

Make of model cometVCT-10

Engine type Four-stroke, CI, direct

injection,

water cooled twin

cylinder, constant Speed

engine

Bore (mm) 80



Bore (mm) 80

Stroke (mm) 110

Compression ratio 17.5:1

Rated power@1500

rpm(kW)

7.4

Nozzle opening

pressure (bar)

200

Injection timing (CA) 23o BTDC

AVL digas analyzer and smoke density was measured by AVL 437 C diesel smoke meter

RESULTS OF ENGINE PERFORMANCE � Engine was able to run with maximum 50% waste plastic oil- diesel blends. Above 50%

blend, detonations occur in the engine and it started vibrating.

� Brake thermal efficiency (almost same or marginally higher than diesel upto 80% load and somewhat lower at full load)

� Exhaust gas temperature (Exhaust gas temperature is found marginallyhigher with blend than diesel operation)

� Brake specific fuel consumption (Brake specific fuel consumption ismarginally less than diesel)



EMISSION ANALYSIS

� NOx, CO, HC and smoke emissions are found higher than diesel.



Publications:

� PATENT: 1 NO. INDIAN PATENT

� R. K. Singh, A.K. Panda, ‘Catalytic conversion of wastepolypropylene to liquid fuel’ Application no 674/KOL/2011publication date 24/06/2011 Journal No.- 25/2011.



INTERNATIONAL JOURNAL:

1. Achyut K. Panda, R.K.Singh, D.K.Mishra, “Thermolysis of waste plastics to liquid fuel A suitable method for plastic

waste management and production of value added products- A World prospective” Renewable and sustainable energy

Reviews, 14 (1) 2010, 233-248.

2. Achyut K. Panda, D. K. Mishra, B.G.Mishra and R. K. Singh, Effect of Sulphuric acid treatment on the physicochemical

characteristics of Kaolin clay, Colloids and Surfaces A: Physicochemical and Engineering Aspects, Volume 363, Issues 1-3,

20 June 2010, Pages 98-104.

3. Achyut K. Panda and R. K. Singh, Catalytic performances of kaoline and silica alumina in the thermal degradation of

polypropylene, Journal of Fuel Chemistry and Technology, 39(3), 2011, 198-202, Elsevier publications

4. Sachin Kumar, Achyut K. Panda and R.K.Singh, A review on Tertiary recycling of high density polyethylene to fuel,

Resources, Conservation & Recycling, 55 (2011) 893– 910, Elsevier publications.

5. Achyut K. Panda, R.K. Singh, and D.K. Mishra, Thermo-Catalytic Degradation of Thermocol Waste to Value Added

Liquid Products, Asian Journal of Chemistry; Vol. 24, Issue No. 12, 5539 - 5542 (2012)

6. Achyut K. Panda, S.Murugan, R.K.Singh, Performance and emission characteristics of diesel fuel produced from waste



6. Achyut K. Panda, S.Murugan, R.K.Singh, Performance and emission characteristics of diesel fuel produced from waste

plastic oil obtained by catalytic pyrolysis of waste polypropylene, Accepted in Energy Sources A: Recovery, Utilization,

and Environmental Effects, DOI:10.1080/15567036.2013.800924, Taylor and Francis Publications 2013.

7. Sachin Kumar, Achyut K. Panda, R. K. Singh, ‘Preparation and characterization of acid and alkaline treated kaolin clay’

Bulletin of Chemical Reaction Engineering & Catalysis, 8 (1): 61-69, (2013).

8. Achyut K. Panda, R.K.Singh, Optimization of Process Parameters by Taguchi Method: Catalytic degradation of

polypropylene to liquid fuel, International Journal of Multidisciplinary and Current Research (IJMCR) July-August:

2013.

9. Achyut K. Panda, R.K.Singh, Experimental Optimization of Process for the Thermo-Catalytic Degradation of Waste

Polypropylene to Liquid Fuel, Advances in energy engineering (AEE), Science and Engineering Publishing Company. 1

(3), July 2013.

10. Achyut K. Panda, R.K.Singh, Optimization of Process Parameters in the Catalytic degradation of polypropylene to liquid

fuel by Taguchi Method, Accepted in Advanced Chemical Engineering Research(ACER)., Vol:2, Issue: 4, PP.106-112,Science

and Engineering Publishing Company 2013

11. Achyut K. Panda, R.K.Singh, Thermo-catalytic degradation of low density polyethylene to liquid fuel over kaolin catalyst,

Accepted in Int. J. of Environment and Waste Management (IJEWM), Inderscience publications 2013.

CONFERENCE PROCEEDINGS

1. Achyut K. Panda, R. K. Singh, D. K. Mishra, Recycling of waste plastics to liquid fuel; a suitable method for

solid waste management- An Indian and World prospective, Renewable Energy Asia 2008 – An International

Conference & 4th SEE Forum Meeting at IIT Delhi” 11-13, Dec.2008.

2. Achyut K. Panda, R. K. Singh, D. K. Mishra, Feed stock recycling of plastics –A Greener Approach to

plastic Waste Management, SRK-ISA-RC-24- International Conference on Water, Environment, Energy and

Society to be held during 28-30 June 2009, S. R. K. (P.G.) college, Firozabad.

3. Achyut K. Panda and R. K. Singh, Thermolysis of waste thermocol to value added products-2, 2010

International Conference on Environmental Science and Technology April 23-25,2010, Bangkok, Thailand,

(ICEST 2010)

4. Achyut K. Panda, Sachin Kumar, R.K.Singh, Thermolytic conversion of waste plastics to fuels and

chemicals, National conference on Smart materials and 25th annual seminar of Orissa Chemical Society,



chemicals, National conference on Smart materials and 25 annual seminar of Orissa Chemical Society,

from 25-26 Dec. 2010, organised by Apex Institute of Technology and Management Bhubaneswar.

5. Achyut K. Panda, Sachin Kumar, R.K.Singh, Optimization of Process Parameters by Taguchi Method:

Catalytic degradation of polypropylene to liquid fuel, Recent advances in Chemical and Environmental

Engg, NIT Rourkela, 20-21 January 2012

6. Achyut Kumar Panda, R.K.Singh “Thermolytic degradation of waste Omfed milk packets to liquid fuel”. A

National Seminar on frontiers of synthetic polymer science and global economy in 21st century; 21st & 22nd

Sep 2013, S.K.C.G. Autonomous College, Paralakhemundi, Gajapati, Odisha

1. The compelling facts about plastics, Analysis of plastics production, demand and recovery for 2005

in Europe published in and the compelling facts about plastics, Analysis of plastics production, demand

and recovery for 2006 in Europe published in 2008.

2. Buekens AG, Huang H. Catalytic plastics cracking for recovery of gasoline-range hydrocarbons from

municipal plastic wastes. Resources, Conservation and Recycling1998; 23:163–181.Miskolczi N, Bartha

L, Angyal A. High Energy Containing Fractions from Plastic Wastes by Their Chemical Recycling.

Macromol. Symp. 2006; 245–246: 599–606.

3. Hayashi J, Nakahara J, Kusakabe K, Morooka S. Pyrolysis of polypropylene in the presence of oxygen.

Fuel Processing Technology 1998; 55(3): 265-275.

4. Kaminsky W, Predel M, Sadiki A. Feedstock recycling of polymers by pyrolysis in a fluidised bed.

References



4. Kaminsky W, Predel M, Sadiki A. Feedstock recycling of polymers by pyrolysis in a fluidised bed.

Polymer Degradation and Stability 2004; 85(3): 1045-1050.

5. Kiang JKY, Uden PC, Chien JCW. Polymer reactions-Part VII: Thermal pyrolysis of polypropylene.

Polymer Degradation and Stability 1980; 2(2): 113-127.

6. Kim JR, Yoon JH, Park DW. Catalytic recycling of the mixture of polypropylene and polystyrene. Polymer

Degradation and Stability 2002; 76(1): 61-67.

7. Scheirs J, Kaminsky W. Feedstock recycling of waste plastics, John Willy & Sons, Ltd. (2006).

8. A. Corma. Inorganic Solid Acids and Their Use in Acid-Catalyzed Hydrocarbon Reactions. Chem. Rev

1995; 95 (3):559-614.

9. Sivasanker S. Catalysis in petroleum refining. Catalysis; 2002: 362-376.

10. Singh B, Sharma N. Mechanistic implications of plastic degradation. Polymer Degradation and Stability

2008; 93: 561-584.

Any Doubt

Contact: Dr. Achyut Kumar Panda

Email: [email protected]



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Email: [email protected]

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Dr. Achyut Kumar Panda Plastics to Fuel by Dr... · My work at NIT Rourkela Publications References. Waste plastic to fuel-A sustainable approach to energy recovery Dr. Achyut K.

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