Technical Seminar Report ON

FUEL FROM PLASTIC WASTE

Submitted in partial fulfilment of the requirement of the award of the
degree of
BACHELORS OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Under
JNTU HYDERABAD

BY
MOHAMMED AZMATH
16H11A0347
Under the Esteemed Supervision of
MR. NITIN CHANDRA MANAS
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY
Accredited by NAAC, NBA, Approved by AICTE & Affiliated by
JNTU Hyderabad
Survey No. 32, Himayat Sagar, Hyderabad-500019, India.
2019-20
 LORDS INSTITUTE OF ENGINEERING
TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate

This is to certify that Technical Seminar report work entitled -

“FUEL FROM PLASTIC WASTE”, is a bonafide record of
the work successfully completed and submitted by

MOHAMMED AZMATH 16H11A0347

Under the guidance of MR. NITIN CHANDRA MANAS , Assistant

Professor, Mechanical Engineering Department for the Requirement
of partial fulfillment for the award of degree of Bachelor of
Technology in Mechanical Engineering during the academic year
2016-2020 from JNTU-Hyderabad

Mr. Nitin Chandra manas Dr. Syed Azam Pasha Quadri

Internal Guide HOD/Vice Principal

Mr. Mohammed Asif .K

Seminar Coordinator
 Internal Guide HOD/Vice
Principal

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to JNTUH/Estd.2002.

Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Declaration

We hereby declare that the report “FUEL FROM PLASTIC

WASTE “which is being submitted by us In partial fulfilment for the
award of Bachelor of Technology in the Department of Mechanical
Engineering at the Lords Institute of Engineering and Technology,
Telangana-500091, is the result of investigations carried out by us
under the guidance of MR. NITIN CHANDRA MANAS Assistant
professor in Mechanical Engineering Department, Lords Institute of
Engineering and Technology.

The work is original and has not been submitted for any degree
for this or any other university.
 MOHAMMED AZMATH
16H11A0347
LORDS INSTITUTE OF ENGINEERING &
TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Acknowledgement

MOHAMMED
AZMATH
16H11A0347
mdazmath96@gm
ail.com
+918801701965

The successful completion of this report involves many people

and we are extremely grateful to lecturers in mechanical engineering
department for their excellence guidance right from selection of
project and for encouragement throughout the completion of the
project.
 We express our sincere thanks to my supervisor
MR. NITIN CHANDRA MANAS , Assistant Professor,
Lords Institute of Engineering and Technology. The main source for
helping in selection of our project and also suggested the suitable
direction for our project. The guidance showed the path towards the
successful completion of project.

We express our sense of gratitude to Dr. SYED AZAM

PASHA QUADRI Vice Principal/Head of the Mechanical
Engineering Department for his encouragement during the process of
this project work.
We derive great pleasure in expressing our sincere gratitude to
our Technical Seminar coordinator Mr.Mohammed Asif Kattimani.
for his kindly suggestions, which helped us to complete this work
successfully.

LORDS INSTITUTE OF ENGINEERING &TECHNOLOGY

Approved by AICTE/Affiliated to
JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

Seminar Assessment Process

PSO
Professional Skills
Problem- Solving Skills
Course Name: - ME706PC Project Work

CO.1. Exhibit good teamwork skills and serves as effective

members of multi-disciplinary teams
C0.2. Articulate and justify technical solution to diverse audiences
 through oral, written and graphical communication.
CO.3. Analyse the importance of professional and ethical
responsibilities of mechanical engineering.
CO.4. Experimentally analyse the innovative approach with respect
to research &development

PEO
PEO 1: Shall apply fundamental and advance knowledge skills in
basic and engineering science and in Mechanical engineering to find
suitable solution to technology challenges and problem in various
areas of engineering and real life areas using modern tools
PEO 2: Shall practice mechanical engineering in a responsible,
professional, and dedicated manner by functioning effectively either
as an individual or as a member of plenty disciplinary team, for the
benefit of the industry and society at large without detriment to
environment and sustainable development
PEO 3: Shall acquire good job opportunities in industries or pursue
higher studies.
PEO 4: Shall develop the ability to engage in lifelong learning,
research and development in a responsible, professional, dedicated
and ethical manner for the benefit of the industry and society at large.
 Abstract
The increased demand and high price for energy sources are driving
efforts to convert organic compounds into useful hydrocarbon fuels.
Although much of this work has focused on biomass, there are strong
benefits to deriving fuels from waste plastic material. Waste plastic is
abundant and its disposal creates large problems for the environment.
Plastic does not break down in landfills, it is not easily recycled and
degrades in quality during the recycling process, and it can produce
waste ash, heavy metals, and potentially harmful gas emissions if
incinerated at high temperatures. However, thermal processes can be
used to convert plastics into hydrocarbon fuels such as gasoline,
diesel, aviation / jet fuel, which have unlimited applications in airline
industries, helicopter, heavy transportation, and electricity generation.
The method and principal of the production / process will be
discussed.

Keywords: REACTOR, PYROLYSIS, CATALYST, FEEDSTOCK,

ETHYLENE.

Contents

Certificate ii

Declaration iii

Acknowledgement iv

Seminar assessment process v

Abstract vi

Content vii

List of Tables viii

List of figures ix

Abbreviations x

Chapter 1. Introduction

1. Introduction

1.1. Plastics and selection of plastic

1.2 Effects of waste plastic

Chapter 2. Literature Review

2.0. Literature Review

2.1. Factors Affecting Plastic pyrolysis

2.2 Types of reactor

2.2.1. Batch, semi-batch, and continuous

2.2.2. Fixed Bed and Fluidized Bed reactor

2.3. Use of Catalyst

2.3.1. Advantages of Using Catalyst

2.4. Quality Comparison of Pyrolysis products and petroleum fuels

2.4.1. Comparision of Diesel and Petrol with plastic

Derived Fuels
Chapter 3. Objectives

Chapter 4. Methodology

Existing Commercial Plastic Pyrolysis Technology

4.1 Feeding system

4.2 Pyrolysis

4.2 Product Separation and Collection

Chapter 5.Advantages and applications

Chapter 6. Conclusions and future scope

References

List of Figures

Fig: No.1.SPI code

Fig: No.2.Effects of waste plastics

Fig: No.3. Pyrolysis Reactor

Fig: No.4 Continuous Type reactor

Fig: No.5. Fixed bed reactor

Fig: No.6. Pyrolysis

Fig: No.7.process flow diagram of plastic waste pyrolysis

Fig: No.8. schematic diagram of pyrolysis

Fig.No.9. Applications in various fields

 List of Tables

Table: No.1. Product types of some plastic pyrolysis.

Table: No.2. Comparison of petrol, diesel with plastic derived

Abbreviations
LDPE = Low Density PolyEthylene
HDPE = High Density PolyEthylene
PP = Polypropylene
PVC = Polyvinylchloride
PET = Polyethylene Terephthalate
PS = Polystyrene
 CHAPTER 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
according to their origins.
They are
• Industrial
• Municipal

1.2 PLASTICS
As a brief introduction to plastics, it can be said that plastics are
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 are made of a series of repeating units known as monomers.
Therefore polymers can be moulded 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 PVC
• Thermosets or thermosetting plastics can melt and take shape only
once. They are not suitable for repeated heat treatments; therefore
after they have solidified, they stay solid.
Examples: Phenol formaldehyde and urea formaldehyde.
Society of Plastic Industry (SPI) defined a resin identification code
system that divides plastics into the following seven groups based on
the chemical structure and applications:
1. PET (Polyethylene Terephthalate)
2. HDPE (High Density Polyethylene)
3. PVC (Polyvinyl Chloride)
4. LDPE (Low Density Polyethylene)
5. PP (Polypropylene)
6. PS (Polystyrene) FIG 01

SELECTION OF WASTE PLASTICS

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
 Feedstock of liquid
Main products Type of plastics fuel

Polyethylene (PE) Allowed.

Liquid Polypropylene (PP) Allowed.

Hydrocarbons
Polystyrene (PS) Allowed.

Polymethyl metacrylate
Allowed.
(PMMA)

Acrylonitrile-
Butadiene-
Allowed. But not
suitable.
Styrene

Liquid
Nitrogen-containing
fuel is
Hydrocarbons
obtained. Special
copolymer (ABS) attention
required to cyanide in
oil-
 Not suitable, formation
of
No hydrocarbons Polyvinyl alcohol (PVA)
water and alcohol.

suitable for
Polyoxymethylene Not suitable.
Fuel (POM) Formation of

Table 01 Product types of some plastics pyrolysis

Content of plastics is far lower than the water content of

biomass Such as crops and kitchen wastes.

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. Additionally the effective
conversion requires technologies to be selected according to local
economic, environmental, social and technical characteristic
1.2 EFFECTS OF WASTE PLASTIC

 EFFECTS ON ENVIRONMENT AND

 EFFECTS ON LAND
 EFFECTS ON OCEANS

 EFFECTS ON ANIMALS

 EFFECTS ON HUMANS
 CHAPTER 2

LITERATURE REVIEW ON PLASTIC PYROLYSIS

2.1 FACTORS AFFECTING PLASTIC PYROLYSIS

The major factors influencing the plastic pyrolysis process and

pyrolysis product molecular distribution include chemical
composition of the feedstock, cracking temperature and heating rate,
operation pressure, reactor type, residence time and application of
catalyst.

2.2. TYPES OF REACTOR

The reactor type for the plastic pyrolysis significantly influences

on the heat transfer rate, mixing of plastics with pyrolysis products,
residence time and the reflux level of the primary products. Reactors
can be classified into batch, semi-batch and continuous or classified
based on types of reactor bed.

FIG 03
2.2.1 BATCH, SEMI-BATCH AND CONTINUOUS REACTORS

According to the feeding and product removal processes, the

pyrolysis reactor is categorized into batch, semi-batch and continuous
reactors. In the batch reactor, the materials are fed into the reactor in
batches for pyrolysis either at the start of the process or after all of the
fed materials are processed. In the continuous reactor, the feed
materials are input from one part and the products are led out from the
other part of the reactor. A semi-batch reactor removes the pyrolysis
products continuously once they are generated but the feed materials
are added initially before the pyrolysis process starts. Some semi-
batch process uses inert carrier gas to help remove the pyrolysis
products. Batch and semi-batch reactors are mainly applied on
research, and continuous reactor is mainly for industrial production.
Particular reactions and phenomenon such as secondary pyrolysis
may occur in semi-batch reactors and does not occur in batch reactors.

FIG 04
2.2.2 FIXED BED AND FLUIDIZED BED REACTOR

Based on the heat transfer methods and flow patterns of the feedstock
and products, the pyrolysis reactors can be classified into fixed bed
reactor, fluidized bed reactor and screw kiln reactor. In the fixed bed
reactor, the pyrolysis occurs on a stationary bed which is easy to
design and operate. However, the irregular sizes and shape of the
feedstock plastics may cause feeding problems in continuous process
and the low thermal conductivity of the plastics results in large
temperature gradient in batch process devices. In some systems, the
fixed bed reactors are only used as the secondary pyrolysis reactor.
because the products from the primary pyrolysis are mainly in liquid
and gaseous phase which can be easily fed into the fixed bed.

Fig 05
2.3 USE OF CATALYST

2.3.1 ADVANTAGES OF USING CATALYST

In order to optimize plastic pyrolysis reactions and modify the

distribution of pyrolysis products, catalysts are widely used in
research and industrial pyrolysis processes. Petroleum fuels, such as
LPG, petrol, kerosene, and diesel, are hydrocarbons from C1 to C24.
The PE pyrolysis products are mainly straight hydrocarbons from C1
up to C80, which contain much heavier molecular weight
components. One of the main purposes of using catalysts isto shorten
the carbon chain length of the pyrolysis products and thus to decrease
the boiling point of the products. Catalysts are found to be mainly
applied to PE pyrolysis because the primary product from other
plastics, such as

and PS, are mainly light hydrocarbons, with similar carbon chain
length to the range of commercial fuels. The products from non-
catalytic PE pyrolysis contain high proportion of 1-alkenes and
dialkenes to shorten the carbon chain length of the pyrolysis products
and thus to decrease the boiling point of the products. Catalysts are
found to be mainly applied to PE pyrolysis because the primary
product from other plastics, such as

and PS, are mainly light hydrocarbons, with similar carbon chain
length to the range of commercial fuels.
2.4 QUALITY COMPARISON METHODS OF PYROLYSIS
PRODUCTS AND PETROLEUM FUEL
 PYROLYSIS PROCESS MONITORING
 PRODUCT ANALYSIS METHOD

2.4.1 COMPARISON OF DIESEL AND PETROL WITH

PLASTIC DERIVED FUELS
 CHAPTER 3

Objectives

 The project aims to solve the twin problem of

environmental pollution due to plastic and the need for an
alternative fuel source in the present scenario.

 In this presentation we will discuss on the mountings

problem of plastic disposal for which the plastics are
converted into valuable fuel.

i
 CHAPTER 4

Methodology

4.0 EXISTING PLASTIC PYROLYSIS

TECHNOLOGY

The waste plastic pyrolysis plants were developed and

built in many countries. The selection of pyrolysis technology is
based on the characteristics of the feedstock and the target
products. In general, each pyrolysis technology consists of three
parts:

1. Feeding system,
2. Pyrolysis reactor
3. Separation system.

4.1 FEEDING SYSTEM

In most commercial processes, the raw materials are firstly

heated and melted in the feeding system before flowing into the
reactor. The air, moisture and other solid materials can be
separated from the raw plastic materials in the feeding system.
In addition, the pre-treatment may be required for cracking the
PVC at 250 ºC.
ii
4.2 PYROLYSIS

The description and classification of pyrolysis reactors are

given in Section 2.1 of this thesis and the existing commercial
pyrolysis plants use various types of the reactors. Continuous
pyrolysis process is applied on most commercial plants with
capability to use catalysts in which the plastic retention time is
relatively short.

Very few of the commercial plants use high pressure

operation condition and most of the plants operate at or slightly
above atmospheric pressure. The operating temperature in the
reactors varies largely from 250 ºC (Mazda fixed-bed catalytic
process in Japan) up to 800 ºC (Compact Power fixed-bed
pyrolysis in United Kingdom) but most of the pyrolysis reactors
operate between 400 ºC and 550 ºC.

It must be noted that if the operation temperature is above

800 ºC, the process becomes gasification and the products are
mainly short chain hydrocarbons which remains as gases under
room temperature and atmospheric pressure. All of the
commercial plants are fast or flash pyrolysis. Three types of
reactors including fixed-bed, fluidized-bed, and rotary kiln can
be found in the literature review.

iii
Fig 06

iv
WORKING PROCESS

 The process is a thermo-chemical decomposition of organic

matter at high temperature in absence of oxygen.
 The entire process is undertaken in a closed reactor vessel
followed by condensation process.
 Firstly, the waste plastic is cleaned, shredded and fed into the
Pyrolysis reactor.
 Secondly, heat is applied gradually from 100degree Celsius
to 400 degree Celsius to collect different types of products at
different stages such as liquid fuel, gases, solid residue in the
form of char.
 Catalyst (silica, alimuna, zeolites) are used to control the
conversion processes and improve the quality of fuel.
Finally, the products collected are processed for filtration and
hand-on use

v
fig 07

Fig 08

vi
4.3 PRODUCT SEPARATION AND COLLECTION

The products from the plastic pyrolysis are mainly combustible

gases and liquids. The liquids can be either combusted for
power generation or for further refining to produce high quality
fuels. Diesel range products can then be distilled out as in an oil
refinery process. The non-condensable gases are mainly made of
hydrocarbons, and a minor amount of hydrogen and carbon
monoxide. The gases can be liquefied as fuels, or used as fuels
to heat the pyrolysis reactor, or if the amount is insignificant, the
non-condensable gases are sent to an incinerator flaring off with
the air.

vii
 CHAPTER 5

5.1 ADVANTAGES

1. Eliminates hazards of land pollution by waste

plastic.

2. Waste plastic is converted into high valuable fuel.

3. No need of recycling, all the products are used.

4. Fuels obtained from pyrolysis do not contain oxides.

5. Emissions of harmful gases are equals to NO.

6. No need to preheat the furnace oil if mixed with

plasto- fuel.

7. Plastic waste based fuels can financially effective to

both government and private companies.

viii
5.2 APPLICATIONS

Fig 09

ix
 CHAPTER 6

6.0 Conclusion

Pyrolysis of hydrocarbon polymers is a very complex

process, which consists of hundreds of reactions and products.
Several factors have significant effects on the reactions and the
products.

Based on previous research, this chapter investigated the

fundamental plastic processes and reactions. With temperature
increasing, plastic will go through glassy state, rubbery state,
liquid state, and decomposition. Decomposition of plastic in an
inert environment into liquid is called pyrolysis. There are four
stages of reactions during the plastic pyrolysis process:
initiation, propagation, hydrogen transfer, and termination
reactions.

It was found that heavy molecular weight hydrocarbons

produced from primary cracking can be further cracked into
light molecular weight products through a secondary cracking
process. This secondary cracking process has significantly
influence on the distribution of the product. This process
converts heavy hydrocarbons into gas or light liquid product.
x
6.1 Future Scope

The project shows some light on the possibility of

manufacturing liquid fuels which could be used as feed stock
refinery for further modification or commercial use. By using
this technology we could solve the waste plastic problem and
also significantly reduce the landfills-which are the cause of
infertility of Agriculture land. Waste plastics can also become a
very good source of energy and an alternative to fossil fuel
which have caused an environment imbalance.

xi
References

https://www.researchgate.net/publication/281064326_CONVERSION_O
F_PLASTIC_WASTES_INTO_LIQUID_FUELS_-_A_REVIEW.

Preliminary study on the conversion of different waste plastics into fuel

oil, Munich, GRIN Verlag, http://www.grin.com/en/e-
book/206451/preliminary-study-on-the-conversion-of-differcnt-wastc-
plastics-into-ruel.

European Association of Plastics Recycling website:http://

www.eproplasticsrecycling.org

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.

Oluwafunmilayo A. Aworanti, Samuel E. Agarry, Ayobami O. Ajani.

Advances in Chemical Engineering and Science, 2012
http://dx.doi.org/10.4236/aces.2012.24054 Published Online October
2012 (http://www.SciRP.org/journal/aces)

A. C. Pinto, L. N. G. Lilian, J. C. R. Michelle, M. R. Nu-bia, A. T.

Ednildo, A. L. Wilson, A. de P. P. Pedro and B. de A. Jailson, “Biodiesel:
An Overview,” Journal of the Brazilian Chemical Society, Vol. 16, No.
6b, 2005.

xii
K. Barnwal and M. P. Sharma, “Prospects of Biodiesel Production from
Vegetable Oils in India,” Renewable and Sustainable Energy Reviews,
Vol. 9, No. 4, 2005.

RECOUP, Recycling of Used Plastics webpage: http://www.recoup.org/

Plastics Europe, Plastics the Facts 2013 - An analysis of European latest

plastics production, demand and waste data, October 2013.

Plastics Recyclers Europe, How to boost plastics recycling and increase

resource efficiency – Strategy Paper, 2012.

xiii