WASTE PLASTIC TO FUEL PRODUCTION SYSTEMwastebiofuel.com/.../2019/12/...bionatur-green1-5.pdf · OVERVIEW BIONATUR GREEN SL is the proprietor, sole manufacturer and distributor of

WASTE PLASTIC TO FUEL PRODUCTION SYSTEM

TECHNICAL SPECIFICATIONS AND OPERATIONAL REQUIREMENTS

OVERVIEW

B I O N AT U R G R E E N S L is the proprietor, sole manufacturer a n d distr ibutor of the

Polypetron™ Gen. 5 Waste Plast ic to Fuel Product ion System.

It is a turnkey solution w h i c h c a n b e conveniently a s s e m b l e d onsite at any location

that m e et s our instal lation requirements a n d co m p l i e s w i t h local regulations.

The fifth generat ion Polypetron™ has a capac i ty of p ro d u c i n g 15,000 liters

of pyrolysis c r u de oil per day whi le d i spos ing of 20,000 k i lograms of waste plastic.

Our fully enc losed system is 1 0 0 % eco-friendly, releasing absolutely n o pol lutants

into the environment, a n d p ro d u c i n g zero waste matter. Al l byproducts not sent

to m a r ket are reusable with in the product ion process

CORE ASSUMPTIONS

Cl ient c a n secure l a n d at w h i c h to house the p lant in zones that wo u l d permit this industry. (The Polypetron™ Sys te m emits n o

noxious odors or f u m e s so c a n b e located in c lose vicinity to

residential areas. Operat ion of the e q u i p m e n t does not create any

s o u n d pol lut ion either w i t h s o u n d levels at ≤ 1 2 0 d b )

Sys te m operational 2 4 hours per day, seven days a week, 3 3 0 days a year.

C l ient c a n secure waste p last ic raw mater ia l to m e e t capacity.

The waste p last ic raw mater ia l has b e e n c l e a n e d a n d has a moisture

content of n o m o re t h a n 10%.

Cl ient ca n secure markets for fuel.

Cl ient c a n secure necessary licenses, permissions, a n d m e e t local

regulatory requirements.

THE POLYPETRON™ SYSTEM

The Polypetron™ Sys te m features a cont inuously operat ing screw-type reactor w h i c h is fully enclosed. The system is operational 2 4 hours per day, 3 3 0 days a year (30-35 days of ceased operation per year is required for system maintenance) .

S ta n d a rd configurations of our system inc lude the P P T 2 0 w h i c h m a n a g e s 2 0 metr ic tons of waste p last ic per day, the P P T 4 0 w h i c h hand les 4 0 tons, the P P T 6 0 – 6 0 tons, a n d the P P T 1 0 0 – 1 0 0 tons.

The system is easily scalable by s i m p l y a d d i n g product ion m o d u l e s to the facility, so w e advise c l ients to a l low for expans ion in their product ion p lant p l a n n i n g a n d construction.

Acceptab le feedstock is any type of p last ic except P V C a n d P E T plast ic w h i c h are not re c o m m e n d e d .

Tire, rubber, oil s ludge, a n d m e d i c a l waste c a n also b e used.

A n addit ional feature of our system is that whi le w e guarantee a yield of 15,000 liters of pyrolysis c r u de oil

per day f rom 2 0 tons of c l e a n e d waste plastic, u n c l e a n e d plast ic c a n also b e fed into the system.

This wo u l d s i m p l y s o m e w h a t reduce yield.

THE POLYPETRON™ SYSTEM COMPONENTS AND DEVICES

The standard Polypetron™ Sys te m consists of a co m p l ete set of c o m p o n e nt s to facilitate the process of convert ing sorted a n d c l e a n e d sol id waste p last ic into pyrolysis c r u d e oil. This process involves s h re d d i n g the plastic, dr y ing it, feeding it into the reactor, condensat ion a n d disti l lation of vapor ized plastic, a n d ch a n n e l i n g char a n d R D F (refuse derived fuel – hydrocarbon gas) byproducts b a c k to further heat the reactor. Pyrolysis c r u d e oil c a n b e m a r kete d directly or further refined to p ro d uc e 7 0 % diesel a n d 1 0 % gasol ine for sale, a n d 2 0 % ga s a n d char to b e reused as fuel heat ing the reactor.

Addit ional core c o m p o n e nt s inc lude a S c r u b b e r Syste m for exhaust t reatment so that n o t h i n g is released to the

env ironment other t h a n a m i n o r a m o u n t of waste heat (most heat waste is p u t to use for dr y ing p last ic feedstock).

Opt ional c o m p o n e nt s that c a n b e a d d e d inc lude a Ref in ing Syste m to p ro d uc e E N 5 9 0 grade, low carbon diesel;

a n d waste m a n a g e m e n t systems for sort ing a n d c l e a n i n g waste plastic.

OUR STANDARDIZED SYSTEM COMPONENT LIST INCLUDES:

Not i n c l u d e d are m a i n fuel storage tanks w h i c h c a n b e installed, subject to local regulations. Typically, four 15,000-

liter storage tanks s h o u l d b e onsite for e a c h 2 0 tons of waste p last ic m a n a g e d per day.

1. Pre-treatment, Shredder, a n d Feeder Syste m

2 . C o m b u sto r & Reactor C h a m b e r

3 . S c re w Reactor Type

4 . Condenser Syste m

5 . S c r u b b e r Syste m

6 . Cool ing Tower

7 . C h i m n e y

8 . P i p i n g Syste m

9. E lectr ic Sys te m

10. Instrument Syste m

11. Disti l lation Process

AREA REQUIRED FOR PRODUCTION FACILITY

The product ion p lant property s h o u l d have a m i n i m u m l a n d area of 3,000 square meters, a l t h o u gh 4,000-4,500 square meters

is r e c o m m e n d e d to a l low for expansion.

THE POLYPETRON™ WASTE PLASTIC TO FUEL PRODUCTION SYSTEM IS HOUSED IN TWO MAIN BUILDINGS:

1 . A warehouse for raw mater ia l storage a n d preparat ion w i t h the capaci ty for stor ing three days’ supp ly of waste p last ic feedstock (No temperature control required.) S i ze is d e p e n d e nt u p o n the capaci ty of the plant. Warehouse floor load s h o u l d b e approx imately 1 ,500kg per square meter.

2. The m a i n factory b u i l d i n g w h i c h houses the reactor a n d disti l lation c h a m b e rs (temperature control at 20-30 degrees Celsius)

P lease refer to b u i l d i n g size specif icat ions for e a c h product ion m o d e l in the chart below. For the entry level PPT20, the m a i n reactor footprint is 3 .00m x 6.00m. A cei l ing c learance of 1 0 meters is required a n d the bui ld ing ’s foundat ion m u s t support a m i n i m u m we i ght of 3 ,000kg per square meter.

ADDITIONAL BUILDINGS THAT MIGHT BE NEEDED DEPENDING ON ADMINISTRATIVE

AND LOGISTIC MANAGEMENT OF THE PLANT INCLUDE:

Administrat ive office(s). This wi l l inevitably b e n e e d e d in m o st cases. Offices c a n either b e in a separate b u i l d i n g or converted standard 40-foot container, or h o u s e d as separate ro o ms ins ide the m a i n factory bui ld ing , poss ib ly as a m e z za n i n e floor w i t h w i n d o w s fac ing the m a i n reactor unit for efficient observation a n d oversight of e q u i p m e n t a n d staffs.

L iving /resting quarters, restrooms, d i n i n g areas, conference ro o ms etc.

Storage/maintenance room(s).

Vehicle garage(s) for trucks, forklifts, etc.

SAMPLE FACTORY

LAYOUT PLAN

FOR THE PPT20

POLYPETRON™

WITH EXPANDABILITY

TO THE PPT40

FUELING THE SYSTEM

The reactor unit is heated to h i g h temperature in order to m e l t d o w n a n d cause p last ic

to evaporate before b e i n g disti l led as fuel. R e c o m m e n d e d fuel to heat the reactor is firewood.

This is the m o st e co n o mi ca l opt ion in our prototype system. Other poss ib le heat ing fuels are gas, other fossil fuels, or coal.

ENERGY CONSUMPTION

The entry level P P T 2 0 m o d e l requires 1.75MW of thermal energy per hour. O n c e operation has b e e n initiated, it is a s s u m e d that heat ing of the reactor wi l l ideal ly b e structured

us i n g a co mb i n at i o n of ga s a n d char residue f rom the process, s u p p l e m e nt e d by b i o m a s s in the form

of w o o d pellets.

The ga s a n d char byproducts of our process c a n a c co u nt for a ro u nd 5 0 % of the fuel required to heat the reactor.

Consequent ly a b o u t 2 1 MWt of heat per day wi l l b e prov ided f rom external sources.

E a c h ton of waste p last ic c a n yield 4.8MWt of heat. Therefore 4.7 tons of b i o m a s s (wood pellets) per day wi l l b e required. E lectr ical power c o n s u m p t i o n starts at 5 5 K W per hour for the PPT20, a n d goes u p to 1 5 0 KW/h for the P P T 1 0 0 model .

MANPOWER REQUIREMENTS

For fu l l - f ledged operation of a bas ic P P T 2 0 Polypetron™ p roduct ion module , required m a n p o w e r is as follows:

P lant Manager: 1 (semi-ski l led)

Assistant P lant Manager: 1 (semi-ski l led) Electr ical a n d Mechanica l Technicians: 3 (semi-ski l led)

Factory Staff: 3 (unski l led)

R a w Material Preparat ion a n d Handl ing: 3 (unski l led)

This is a total of e ight persons for operation of m a c h i n e r y a n d the w h o l e industrial process, faci l itating fu l l t ime 24-hours a day operation (three e ight -hour shifts).

D e p e n d i n g o n location, scale a n d local requirements, addit ional staff m i g h t b e n e e d e d for security a n d janitorial work,

b u t ass ign ing the general m a i n t e n a n c e a n d u p k e e p of the factory g r o u n d s a n d m a i n t a i n i n g order s h o u l d b e ab le

to b e m a n a g e d by exist ing staff. Bas ic personnel n e e d e d w o u l d inc lude c lerks/accounting staffs to h a n d l e

all f inancial b o o k k e e p i n g as wel l as inventory, purchas ing, sales, communicat ions , etc.

Ful l - f ledged corporate operation w o u l d require addit ional posit ions to b e filled, of course.

This w o u l d d e p e n d a lot u p o n scale a n d m a g n i t u d e of operations, c o m p a n y structure,

f inancial m a n a g e m e n t , m a r k e t i n g model , raw mater ia l sourcing, etc.

QUALITY OF FUEL PRODUCED

Our pyrolysis c r u d e oil is equivalent to fuel oil w h i c h c a n b e u s e d as is for heavy machinery.

For refining into diesel, our pyrolysis oil is superior to l ight c r u d e oil in that it yields 7 0 % E N 5 9 0 grade,

low carbon diesel, whereas l ight c r u d e oil typical ly produces only a b o u t 5 5 % d u e to substant ia l b i t u m e n content.

Case studies of the use of our fuel by b u s companies , refineries, a n d agricultural industry, has rendered

a satisfied response f rom customers w h o have found our diesel to b e of h i g h quality.

I n d e p e n d e nt laboratory test results of our fuel released by Intertek a n d C h u l a l o n gkorn University

are attached as a n a p p e n d i x to this d o c u m e nt .

FUEL OUTPUT MARKETS

The pr imar y fuel p ro d u c e d by our system – pyrolysis c r u d e oil – c a n b e so ld to petro leum c o m p a n i e s a n d distr ibutors

in the o p e n m a r ket to b e refined a c co rd i ng to their formulae. There is h i g h d e m a n d in s u c h markets especial ly

w i t h recently a d o pte d E u ro p e a n Par l iament regulat ions requir ing the inclus ion of at least 1 .5% “advanced biofuel”

in all fuel so ld by 2021, a n d 1 0 % in by 2030. Waste-based fossil fuel ( w h i c h is w h a t pyrolysis c r u d e oil is) is stated

as a g o o d exa m p l e of a d va n c e d biofuel.

Alternatively, our fuel c a n b e so ld directly as fuel oil for heavy machinery, or further refined as diesel for retail to p u b l i c or n i c h e markets, s u c h as transport companies , train companies , airlines, logist ics companies , generat ing facilities etc.

The s u p p l e me nta r y 1 0 % of gasol ine p ro d u c e d by the process c a n also b e so ld or u s e d internally to offset energy costs.

WARRANTY AND SERVICE

B I O N AT U R G R E E N S L . shal l oversee all aspects of the construction, sett ing up, a n d c o m m i s s i o n i n g of the Polypetron™. Furthermore, S e p c o wi l l provide comprehens ive onsite a n d offsite training of all operators of our system to ensure extensive s m o o t h operation.

B I O N AT U R G R E E N guarantees all c o m p o n e nt s of the Polypetron™ to b e free of defects a n d offers a co m p l ete condit ional warranty of the system for a per iod of 1 year f rom the date of commiss ion ing .

Our stated Service Life E x p e c ta n c y of the Polypetron™ is 10-15 years, b u t actua l service life is expected to extend wel l b eyo n d that. Our first generat ion Polypetron™ has m a i nta i n e d operation for m o re t h a n 1 5 years. Sys te m m a i nte n a n c e a n d spare parts rep lacement are offered at reasonable cost throughout e q u i p m e n t lifespan.

INTERNATIONAL STANDARD COMPLIANCE

The Polypetron™ is co m p l i a nt w i t h n u m e ro u s international

regulatory standards, i n c l u d i n g BS, EN, DIN, ASMT, etc.

BASIC PARAMETERS OF THE POLYPETRON™ WASTE PLASTIC PYROLYSIS SYSTEM

Model P P T 2 0 P P T 4 0 P P T 6 0 P P T 1 0 0

Dai ly P last i c Waste M a n a g e m e n t C a p a c i t y 2 0 Tons 4 0 Tons 6 0 Tons 1 0 0 Tons

P r o d u c t Pyrolysis C r u d e Oi l - Tons 14.15 28.29 42.44 70.73

P r o d u c t Pyrolysis C r u d e Oi l - Liters 16,940.10 33,880.20 50,820.40 84,700.60

Product: S o l i d (Char) – Tons 2.83 5.66 8.49 14.15

Product: Gas – Tons 1.89 3.77 5.66 9.43

W o r k i n g Method S crew -T ype Reactor: Fu l ly C o n t i n u o u s

R a w Materials Waste Plast ic , Tire, Rubber , O i l S ludge , Medica l Waste

N u m b e r of Reactors 2 x 8 sets 4 x 8 sets 6 x 8 sets 1 0 x 8 sets

S i z e of Reactor (D iameter x L e n g t h ) 0 .30X4.00m

Pattern Hor i zonta l S c r e w

H e a t i n g Materials Coal, Charcoal , Wood, F ue l Oil, Natura l Gas, LPG, RDF , etc.

Total E lectr ica l P o w e r 55kw/h 80kw/h 120kw/h 150kw/h

T hermal 1.75MW 3.25MW 4.75MW 7.85MW

L a n d Area 3 ,000S qM 3 ,000S qM 3 ,500S qM 4 ,500S qM

Floor Area 3 0 X 2 5 m 3 5 X 2 5 m 4 0 X 2 5 m 5 6 X 2 5 m

Roof Area (L*W*H) 2 0 X 1 5 X 1 0 m 2 5 X 1 5 X 1 0 m 3 0 X 1 5 X 1 0 m 4 6 X 1 5 X 1 0 m

O perat ing Pressure N o r m a l Pressure

C o o l i n g Method Water C o o l i n g

Serv ice Life 1 0 -1 5 Years

DIESEL AND BYPRODUCT OUTPUT WITH OPTIONAL DISTILLATION SYSTEM INSTALLATION

P r o d u c t (Liquid): Diese l – Liters 11,858.08 23,716.17 35,574.25 59,290.42

P r o d u c t (Liquid): B e n z e n e – Liters 1,711.43 3,422.87 5,134.30 8,557.17

P r o d u c t (Solid): C h a r – Tons 0.99 1.98 2.97 4.95

Product: Gas – Tons 1.41 2.83 4.24 7.07

OIL RATIO OBTAINED FROM VARIOUS RAW MATERIALS BY THE POLYPETRON™ SYSTEM

R a w Material Oi l Rat i o

P E 5 0 % - 7 5 %

P P 5 0 % - 7 5 %

P S 5 0 % - 7 5 %

A B S 4 0 %

Plast ic c a b l e 8 0 %

Plast ic b a g 5 0 %

P V C N o t R e c o m m e n d

P E T N o t R e c o m m e n d

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