FUEL FROM PLASTIC WASTE

Department of mechanical engineering, laqshya Institute of technology & sciences, thanikella, telangana,
Email id: saikumar.pusuluri999@gmail.com,
Name : p.saikumar
R.no : 14RC1A0342

Abstract
Economic growth and changing consumption and production patterns are resulting into rapid increase in
generation of waste plastics in the world. On the other hand, plastic waste recycling can provide an opportunity to
collect and dispose of plastic waste in the most environmental friendly way and it can be converted into a resource.
In most of the situations, plastic waste recycling could also be economically viable, as it generates resources,
which are in high demand. This paper is an effort for the conversion of plastics into fuel which is in commercial
use, under pilot implementation and under laboratory testing, aimed to raise awareness on available options. The
results of hydrolysis of plastic has compared without catalyst and with catalyst. Catalyst used here were Calcium
Antonito and Zealot. Calcium Antonito has proved better for the conversion of LDPE to liquid fuel. The kinetic
study has also carried out by different models and reaction follows Maple’s first order reaction.

Introduction: Plastics will break before deforming and therefore

are not plastic in the technical sense there are two
types of plastics: thermoplastics and thermosetting
polymers. Thermoplastics will soften and melt if
enough heat is applied; examples are polyethylene,
polystyrene, polyvinyl chloride and
polytetrafluoroethylene (PTFE). Thermosets can
melt and take shape once; after they have solidified,
they stay solid.

Overview:

Plastics can be classified by chemical

structure, namely the molecular units that make up
the polymer's backbone and side chains. Some
important groups in these classifications are the
Fig:Household items made of various kinds of acrylics, polyesters, silicones, polyurethanes, and
plastic. halogenated plastics. Plastics can also be classified
by the chemical process used in their synthesis, such
as condensation, polyaddition, and cross-linking.
Plastic:

Other classifications are based on

It is the general common term for a wide
range of synthetic or semisynthetic organic
amorphous solid materials used in the manufacture
of industrial products. Plastics are typically
polymers of high molecular mass, and may contain
other substances to improve performance and/or
reduce costs. Monomers of Plastic are either natural
or synthetic organic compounds. The word is
derived from the Greek plastics meaning fit for
molding (plasters) meaning molded. It refers to their
malleability, or plasticity during manufacture, that
allows them to be cast, pressed, or extruded into a
variety of shapes—such as films, fibers, plates,
tubes, bottles, boxes, and much more. The common
word plastic should not be confused with the
technical adjective plastic, which is applied to any
material which undergoes a permanent change of
shape (plastic deformation) when strained beyond a
certain point. Aluminum, for instance, is plastic in
this sense, but not a plastic in the common sense; in
contrast, in their finished forms, some
qualities that are relevant for manufacturing or
product design. Examples of such classes are the
thermoplastic and thermoset, elastomer, structural,
biodegradable, and electrically conductive. Plastics
can also be classified by various physical properties,
such as density, tensile strength, glass transition
temperature, and resistance to various chemical
products.
Due to their relatively low cost, ease of
manufacture, versatility, and imperviousness to
water, plastics are used in an enormous and
expanding range of products, from paper clips to
spaceships. They have already displaced many
traditional materials, such as wood; stone; horn and
bone; leather; paper; metal; glass; and ceramic, in
most of their former uses.
The use of plastics is constrained chiefly
by their organic chemistry, which seriously limits
their hardness, density, and their ability to resist
heat, organic solvents, oxidation, and ionizing
radiation. In particular, most plastics will melt or
decompose when heated to a few hundred degrees
celsius.While plastics can be made electrically
conductive to some extent, they are still no match
for metals like copper or aluminum. Plastics are still
too expensive to replace wood, concrete and
ceramic in bulky items like ordinary buildings,
bridges, dams, pavement, and railroad ties.
Chemical structure:
Common thermoplastics range from 20,000 to
500,000 in molecular mass, while thermosets are
assumed to have infinite molecular weight. These
chains are made up of many repeating molecular
units, known as repeat units, derived from
monomers; each polymer chain will have several
thousand repeating units. The vast majority of
plastics are composed of polymers of carbon and
hydrogen alone or with oxygen, nitrogen, chlorine
or sulfur in the backbone. (Some of commercial
interests are silicon based.) The backbone is that
part of the chain on the main “path” linking a large
number of repeat units together. To customize the
properties of a plastic, different molecular groups
“hang” from the backbone (usually they are “hung”
as part of the monomers before linking monomers
together to form the polymer chain). This fine
tuning of the properties of the polymer by repeating
unit’s molecular structure has allowed plastics to
become such an indispensable part of twenty first-
century world.
Some plastics are partially crystalline and partially
amorphous in molecular structure, giving them both
a melting point (the temperature at which the
attractive intermolecular forces are overcome) and
one or more glass transitions (temperatures above
which the extent of localized molecular flexibility is
substantially increased). The so-called semi-
crystalline plastics include polyethylene,
polypropylene, poly (vinyl chloride), polyamides
(nylons), polyesters and some polyurethane. Many
plastics are completely amorphous, such as
polystyrene and its copolymers, poly (methyl
methacrylate), and all thermosets.
fig.1: plastic food
Molded plastic food replicas on display outside a
restaurant in Japan.
History:
The first human-made plastic was invented by
Alexander Parks in 1855 [7]; he called this plastic
Parke sine (later called celluloid). The development
of plastics has come from the use of natural plastic
materials (e.g., chewing gum, shellac) to the use of
chemically modified natural materials (e.g., rubber,
nitrocellulose, collagen, calamite) and finally to
completely synthetic molecules (e.g., bakelite,
epoxy, polyvinyl chloride,
polyethylene).
Types:
Cellulose-based plastics
In 1855, an Englishman from Birmingham
named Alexander Parks developed a synthetic
replacement for ivory which he marketed under the
trade name Parke sine, and which won a bronze
medal at the 1862 World's fair in London. Parke
sine was made from cellulose (the major component
of plant cell walls) treated with nitric acid and a
solvent. The output of the process (commonly
known as cellulose nitrate or pyroxilin) could be
dissolved in alcohol and hardened into a transparent
and elastic material that could be molded when
heated. By incorporating pigments into the product,
it could be made to resemble ivory.
Bois Doric is a plastic molding material
based on cellulose. It was patented in Paris by
Lesage in 1855. It is made from finely ground wood
flour mixed with a binder, either egg or blood
albumen, or gelatin. The wood is probably either
ebony or rose wood, which gives a black or brown
resin. The mixture is dried and ground into a fine
powder. The powder is placed in a steel mould and
compressed in a powerful hydraulic press whilst
being heated by steam. The final product has a
highly polished finish imparted by the surface of the
steel mould.
Bakelite:
The first plastic based on a synthetic
polymer was made from phenol and formaldehyde,
with the first viable and cheap synthesis methods
invented in 1909 by Leo Hendrix Baekeland, a
Belgian-born American living in New York state.
Baekeland was searching for an insulating shellac to
coat wires in electric motors and generators. He
found that mixtures of phenol (C6H5OH) and
formaldehyde (HCOH) formed a sticky mass when
mixed together and heated, and the mass became
extremely hard if allowed to cool. He continued his
investigations and found that the material could be
mixed with wood flour, asbestos, or slate dust to
create "composite" materials with different
properties. Most of these compositions were strong
and fire resistant. The only problem was that the
material tended to foam during synthesis, and the
resulting product was of unacceptable quality.
Baekeland built pressure vessels to force out the
bubbles and provide a smooth, uniform product. He
publicly announced his discovery in 1912, naming it
bakelite. It was originally used for electrical and
mechanical parts, finally coming into widespread
use in consumer goods in the 1920s. When the
Bakelite patent expired in 1930, the Catalan
Corporation acquired the patent and began
manufacturing Catalan plastic using a different
process that allowed a wider range of coloring.
Bakelite was the first true plastic. It was a
purely synthetic material, not based on any material
or even molecule found in nature. It was also the
first thermosetting plastic. Conventional
thermoplastics can be molded and then melted
again, but thermoset plastics form bonds between
polymers strands when cured, creating a tangled
matrix that cannot be undone without destroying the
plastic. Thermoset plastics are tough and
temperature resistant.
Bakelite was cheap, strong, and durable. It
was molded into thousands of forms, such as radios,
telephones, clocks, and billiard balls. The U.S.
government even considered making one-cent coins
out of it when World War II caused a copper
shortage. Phenol plastics have been largely replaced
by cheaper and less brittle plastics, but they are still
used in applications requiring its insulating and
heat-resistant properties. For example, some
electronic circuit boards are made of sheets of paper
or cloth impregnated with phenol resin. Phenol
sheets, rods and tubes are produced in a wide
variety of grades under various brand names. The
most common grades of industrial phenolic are
Canvas, Linen and Paper.
Polystyrene and PVC:
Fig.2: polystyrene and PVC
Plastic piping and fire stops being
installed at Norton Casitas, North York (Now
Toronto), Ontario, Canada. Certain plastic pipes can
be used in some non-combustible buildings,
provided they are fire stopped properly and that the
flame spread ratings comply with the local building
code.
After the First World War, improvements in
chemical technology led to an explosion in new
forms of plastics. Among the earliest examples in
the wave of new plastics were polystyrene (PS) and
polyvinyl chloride (PVC), developed by IG Fabre of
Germany.
Polystyrene is a rigid, brittle, inexpensive plastic
that has been used to make plastic model kits and
similar knick-knacks. It would also be the basis for
one of the most popular "foamed" plastics, under the
name styrene foam or Styrofoam. Foam plastics can
be synthesized in an "open cell" form, in which the
foam bubbles are interconnected, as in an absorbent
sponge, and "closed cell", in which all the bubbles
are distinct, like tiny balloons, as in gas-filled foam
insulation and flotation devices. In the late 1950s,
high impact styrene was introduced, which was not
brittle. It finds much current use as the substance of
toy figurines and novelties.
PVC has side chains incorporating
chlorine atoms, which form strong bonds. PVC in
its normal form is stiff, strong, heat and weather
resistant, and is now used for making plumbing,
gutters, house siding, enclosures for computers and
other electronics gear. PVC can also be softened
with chemical processing, and in this form it is now
used for shrink-wrap, food packaging, and rain gear.
Nylon:
The real star of the plastics industry in the
1930s was polyamide (PA), far better known by its
trade name nylon. Nylon was the first purely
synthetic fiber, introduced by DuPont Corporation
at the 1939 World's Fair in New York City.
In 1927, DuPont had begun a secret
development project designated Fiber66, under the
direction of Harvard chemist Wallace Carothers and
chemistry department director Elmer Keiser Bolton.
Carothers had been hired to perform pure research,
and he worked to understand the new materials'
molecular structure and physical properties. He took
some of the first steps in the molecular design of the
materials. His work led to the discovery of synthetic
nylon fiber, which was very strong but also very
flexible. The first application was for bristles for
toothbrushes. However, Du Pont's real target was
silk, particularly silk stockings. Carothers and his
team synthesized a number of different polyamides
including polyamide 6.6 and 4.6, as well as
polyesters.[9]
General condensation polymerization reaction for
nylon. It took DuPont twelve years and US$27
million to refine nylon, and to synthesize and
develop the industrial processes for bulk
manufacture. With such a major investment, it was
no surprise that Du Pont spared little expense to
promote nylon after its introduction, creating a
public sensation, or "nylon mania".
Nylon mania came to an abrupt stop at the end of
1941 when the USA entered World War II. The
production capacity that had been built up to
produce nylon stockings, or just nylons, for
American women was taken over to manufacture
vast numbers of parachutes for fliers and
paratroopers. After the war ended, DuPont went
back to selling nylon to the public, engaging in
another promotional campaign in 1946 that resulted
in an even bigger craze, triggering the so called
nylon riots.
Subsequently polyamides 6, 10, 11, and 12 have
been developed based on monomers which are ring
compounds; e.g. caprolactam.nylon 66 is a material
manufactured by condensation polymerization.
Nylons still remain important plastics, and not just
for use in fabrics. In its bulk form it is very wear
resistant, particularly if oil-impregnated, and so is
used to build gears, plain bearings, and because of
good heat-resistance, increasingly for under-the-
hood applications in cars, and other mechanical
parts.
Rubber:
Natural rubber is an elastomer (an elastic
hydrocarbon polymer) that was originally derived
from latex, a milky colloidal suspension found in
the sap of some plants. It is useful directly in this
form (indeed, the first appearance of rubber in
Europe is cloth waterproofed with unvulcanized
latex from Brazil) but, later, in 1839, Charles
Goodyear invented vulcanized rubber; this a form of
natural rubber heated with, mostly, sulfur forming
cross-links between polymer chains (vulcanization),
improving elasticity and durability.
Synthetic rubber:
The first fully synthetic rubber was synthesized by
Leedey in 1910. In World War II, supply blockades
of natural rubber from South East Asia caused a
boom in development of synthetic rubber, notably
Styrene-butadiene rubber (a.k.a. Government
Rubber-Styrene). In 1941, annual production of
synthetic rubber in the U.S. was only 231 tons
which increased to 840 000 tons in 1945. In the
space race and nuclear arms race, Caltech
researchers experimented with using synthetic
rubbers for solid fuel for rockets. Ultimately, all
large military rockets and missiles would use
synthetic rubber based solid fuels, and they would
also play a significant part in the civilian space
effort.
Toxicity:
Due to their insolubility in water and
relative chemical inertness, pure plastics generally
have low toxicity in their finished state, and will
pass through the digestive system with no ill effect
(other than mechanical damage or obstruction).
However, plastics often contain a variety
of toxic additives. For example, plasticizers like
adipates and phthalates are often added to brittle
plastics like polyvinyl chloride (PVC) to make them
pliable enough for use in food packaging, children's
toys and teethers, tubing, shower curtains and other
items. Traces of these chemicals can leach out of the
plastic when it comes into contact with food. Out of
these concerns, the European Union has banned the
use of DEHP (di-2-ethylhexyl phthalate), the most
widely used plasticizer in PVC. Some compounds
leaching from polystyrene food containers have
been found to interfere with hormone functions and
are suspected human carcinogens.
Moreover, while the finished plastic may
be non-toxic, the monomers used in its manufacture
may be toxic; and small amounts of those chemical
may remain trapped in the product. The World
Health Organization's International Agency for
Research on Cancer (IARC) has recognized the
chemical used to make PVC, vinyl chloride, as a
known human carcinogen. Some polymers may also
decompose into the monomers or other toxic
substances when heated.
The primary building block of
polycarbonates, bisphenol A (BPA), is an estrogen-
like endocrine disruptor that may leach into food.
Research in Environmental Health Perspectives
finds that BPA leached from the lining of tin cans,
dental sealants and polycarbonate bottles can
increase body weight of lab animals' offspring. A
more recent animal study suggests that even low-
level exposure to BPA results in insulin resistance,
which can lead to inflammation and heart disease.
As of January 2010, the LA Times
newspaper reports that the United States FDA is
spending $30 million to investigate suspicious
indications of BPA being linked to cancer. Bis(2-
ethylhexyl) adipate, present in plastic wrap based on
PVC, is also of concern, as are the volatile organic
compounds present in new car smell.
The European Union has a permanent ban
on on the use of phthalates in toys. In 2009, the
United States government banned certain types of
phthalates commonly used in plastic.

Environmental issues:
Plastics are durable and degrade very
slowly; the molecular bonds that make plastic so
durable make it equally resistant to natural
processes of degradation. Since the 1950s, one
billion tons of plastic has been discarded and may
persist for hundreds or even thousands of years. In
some cases, burning plastic can release toxic fumes.
Burning the plastic polyvinyl chloride (PVC) may
create dioxin. Also, the manufacturing of plastics
often creates large quantities of chemical pollutants.
Prior to the ban on the use of CFCs in
extrusion of polystyrene (and general use, except in
life-critical fire suppression systems; see Montreal
Protocol), the production of polystyrene contributed
to the depletion of the ozone layer; however, non-
CFCs are currently used in the extrusion process.
By 1995, plastic recycling programs were
common in the United States and elsewhere.
Thermoplastics can be remolded and reused, and
thermoset plastics can be ground up and used as
filler, though the purity of the material tends to
degrade with each reuse cycle. There are methods
by which plastics can be broken back down to a
feedstock state.
To assist recycling of disposable items,
the Plastic Bottle Institute of the Society of the
Plastics Industry devised a now-familiar scheme to
mark plastic bottles by plastic type. A plastic
container using this scheme is marked with a
triangle of three cyclic arrows, which encloses a
number giving the plastic type:
Plastics type marks: the resin identification code;
1. PET (PETE), polyethylene terephthalate:
Commonly found on 2-liter soft drink bottles, water
bottles, cooking oil bottles, peanut butter jars.
2. HDPE, high-density polyethylene: Commonly
found on detergent bottles, milk jugs.
3. PVC, polyvinyl chloride: Commonly found on
plastic pipes, outdoor furniture, siding, floor tiles,
shower curtains, clamshell packaging.
4. LDPE, low-density polyethylene: Commonly
found on dry-cleaning bags, produce bags, trash can
liners, and food storage containers.
5. PP, polypropylene: Commonly found on bottle
caps, drinking straws, yogurt containers.
6. PS, polystyrene: Commonly found on "packing
peanuts", cups, plastic tableware, meat trays, take-
away food clamshell containers
7. OTHER, other: This plastic category, as its name
of "other" implies, is any plastic other than the
named #1–#6, commonly found on certain kinds of
food containers, Tupperware, and Nalgene bottles.
Unfortunately, recycling plastics has proven
difficult. The biggest problem with plastic recycling
is that it is difficult to automate the sorting of plastic
waste, and so it is labor intensive. Typically,
workers sort the plastic by looking at the resin
identification code, though common containers like
soda bottles can be sorted from memory. Other
recyclable materials, such as metals, are easier to
process mechanically. However, new mechanical
sorting processes are being utilized to increase
plastic recycling capacity and efficiency.
While containers are usually made from a single
type and color of plastic, making them relatively
easy to sort out, a consumer product like a cellular
phone may have many small parts consisting of over
a dozen different types and colors of plastics. In a
case like this, the resources it would take to separate
the plastics far exceed their value and the item is
discarded. However, developments are taking place
in the field of Active Disassembly, which may
result in more consumer product components being
re-used or recycled. Recycling certain types of
plastics can be unprofitable, as well. For example,
polystyrene is rarely recycled because it is usually
not cost effective. These unrecycled wastes are
typically disposed of in landfills, incinerated or used
to produce electricity at waste-to-energy plants.
Biodegradable (Compostable) plastics:
Research has been done on biodegradable
plastics that break down with exposure to sunlight
(e.g., ultra-violet radiation), water or dampness,
bacteria, enzymes, wind abrasion and some
instances rodent pest or insect attack are also
included as forms of biodegradation or
environmental degradation. It is clear some of these
modes of degradation will only work if the plastic is
exposed at the surface, while other modes will only
be effective if certain conditions exist in landfill or
composting systems. Starch powder has been mixed
with plastic as a filler to allow it to degrade more
easily, but it still does not lead to complete
breakdown of the plastic. Some researchers have
actually genetically engineered bacteria that
synthesize a completely biodegradable plastic, but
this material, such as Bhopal, is expensive at
present. The German chemical company BASF
makes Colfax, a fully biodegradable polyester for
food packaging applications.
Bioplastics:
Some plastics can be obtained from biomass,
including:
1. from pea starch film with trigger biodegradation
properties for agricultural applications (TRIGGER).
2. from biopetroleum.
Oxo-biodegradable:
Oxo-biodegradable (OBD) plastic is
polyolefin plastic to which has been added very
small (catalytic) amounts of metal salts. As long as
the plastic has access to oxygen (as in a littered
state), these additives catalyze the natural
degradation process to speed it up so that the OBD
plastic will degrade when subject to environmental
conditions. Once degraded to a small enough
particle they can interact with biological processes
to produce to water, carbon dioxide and biomass.
The process is shortened from hundreds of years to
months for degradation and thereafter
biodegradation depends on the micro-organisms in
the environment. Typically this process is not fast
enough to meet ASTM D6400 standards for
definition as compostable plastics.
Price, environment, and the future:
The biggest threat to the conventional
plastics industry is most likely to be environmental
concerns, including the release of toxic pollutants,
greenhouse gas, litter, biodegradable and non-
biodegradable landfill impact as a result of the
production and disposal of petroleum and
petroleum-based plastics. Of particular concern has
been the recent accumulation of enormous
quantities of plastic trash in ocean gyres.
For decades one of the great appeals of
plastics has been their low price. Yet in recent years
the cost of plastics has been rising dramatically. A
major cause is the sharply rising cost of petroleum,
the raw material that is chemically altered to form
commercial plastics. With some observers
suggesting that future oil reserves are uncertain, the
price of petroleum may increase further. Therefore,
alternatives are being sought. Oil shale and tar oil
are alternatives for plastic production but are
expensive. Scientists are seeking cheaper and better
alternatives to petroleum-based plastics, and many
candidates are in laboratories all over the world.
One promising alternative may be fructose.
Common plastics and uses:
A chair made with a polypropylene seat
Polypropylene (PP)
Food containers, appliances, car fenders (bumpers),
plastic pressure pipe systems.
Polystyrene (PS)
Packaging foam, food containers, disposable cups,
plates, and cutlery, CD and cassette boxes.
High impact polystyrene (HIPS)
Fridge liners, food packaging, vending cups.
Acrylonitrile butadiene styrene (ABS)
Electronic equipment cases (e.g., computer
monitors, printers, keyboards), drainage pipe.
Polyethylene terephthalate (PET)
Carbonated drinks bottles, jars, plastic film,
microwavable packaging.
Polyester (PES)
Fibers, textiles.
Polyamides (PA) (Nylons)
Fibers, toothbrush bristles, fishing line, under-the-
hood car engine mouldings.
Polyvinyl chloride (PVC)
Plumbing pipes and guttering, shower curtains,
window frames, flooring.
Polyurethanes (PU)
Cushioning foams, thermal insulation foams,
surface coatings, printing rollers. (Currently 6th or
7th most commonly used plastic material, for
instance the most commonly used plastic found in
cars).
Polycarbonate (PC)
Compact discs, eyeglasses, riot shields, security
windows, traffic lights, lenses.
Polyvinylidene chloride (PVDC) (Saran)
Food packaging.
Polyethylene (PE)
Wide range of inexpensive uses including
supermarket bags, plastic bottles.
Polycarbonate/Acrylonitrile Butadiene Styrene
(PC/ABS)
A blend of PC and ABS that creates a stronger
plastic. Used in car interior and exterior parts, and
mobile phone bodies.
Special-purpose plastics:
Polymethyl methacrylate (PMMA)
Contact lenses, glazing (best known in this form by
its various trade names around the world; e.g.,
Perspex, Oroglas, Plexiglas), aglets, fluorescent
light diffusers, rear light covers for vehicles.
Polytetrafluoroethylene (PTFE)
Heat-resistant, low-friction coatings, used in things
like non-stick surfaces for frying pans, plumber's
tape and water slides. It is more commonly known
as Teflon.
Polyetheretherketone (PEEK) (Polyetherketone)
Strong, chemical- and heat-resistant thermoplastic,
biocompatibility allows for use in medical implant
applications, aerospace mouldings. One of the most
expensive commercial polymers.
Polyetherimide (PEI) (Ultem)
A high temperature, chemically stable polymer that
does not crystallize.
Phenolics (PF) or (phenol formaldehydes)
High modulus, relatively heat resistant, and
excellent fire resistant polymer. Used for insulating
parts in electrical fixtures, paper laminated products
(e.g., Formica), thermally insulation foams. It is a
thermosetting plastic, with the familiar trade name
Bakelite, that can be moulded by heat and pressure
when mixed with a filler-like wood flour or can be
cast in its unfilled liquid form or cast as foam (e.g.,
Oasis). Problems include the probability of
mouldings naturally being dark colours (red, green,
brown), and as thermoset difficult to recycle.
Urea-formaldehyde (UF)
One of the aminoplasts and used as a multi-
colorable alternative to phenolics. Used as a wood
adhesive (for plywood, chipboard, hardboard) and
electrical switch housings.
Melamine formaldehyde (MF)
One of the aminoplasts, and used as a multi-
colorable alternative to phenolics, for instance in
mouldings (e.g., break-resistance alternatives to
ceramic cups, plates and bowls for children) and the
decorated top surface layer of the paper laminates
(e.g., Formica).
Polylactic acid (PLA)
A biodegradable, thermoplastic found converted
into a variety of aliphatic polyesters derived from
lactic acid which in turn can be made by
fermentation of various agricultural products such
as corn starch, once made from dairy products.
Plastarch material
Biodegradable and heat resistant, thermoplastic
composed of modified corn starch.
Effects of Plastics:
In this era of many astonishing industrial
developments, probably no industry has under gone
such rapid growth and development as the plastics
industry. According to most authorities in this field,
the plastics industry really began in 1868. A young
American printer, named John Wesley Hyatt, was
searching for a new material to be used as a
substitute for ivory in the making of billiard balls.
This new plastic was called Bakelite.
Many new plastics have been made since Bakelite.
Production of plastics has increased over 2000%
since Bakelite was first produced, and there are now
more than twenty known types.
Research along the lines of plastics has
given a great impetus to research and invention in
many other different fields of endeavor. Millions of
dollars are spent yearly in plastics research, trying to
find new plastics and to improve the existing ones.
Much research will be done in the future to lower
the cost of producing plastics so that their
consumption will become greater. In spite of the
varied and widespread application of plastics in
practically every phase of everyday life, the
possibilities of this wonderful new material have
been by no means exhausted. It seems safe to say
that if the application and use of plastics continue to
increase at the present rate, we may be living in a
"Plastics Age."
An apt definition of plastics has been
given by the head of the Monsanto Plastics
Research who says, "Plastics are materials that,
while being processed, can be pushed into almost
any desired shape and then retain that shape."
The major chemicals used to make plastic
resins pose serious risks to public health and safety.
Many of the chemicals used in large volumes to
produce plastics are highly toxic.Some chemicals,
like benzene and vinyl chloride, are known to cause
cancer in humans; many tend to be gases and liquid
hydrocarbons, which readily vaporize and pollute
the air. Many are flammable and explosive. Even
the plastic resins themselves are flammable and
have contributed to numerous chemical accidents.
The production of plastic emits substantial amounts
of toxic chemicals(eg. ethylene oxide, benzene and
xylenes) to air and water. Many of the toxic
chemicals released in plastic production can cause
cancer and birth defects and damage the nervous
system, blood, kidneys and immune systems. These
chemicals can also cause serious damage to
ecosystems.
Ethylene oxide is used as a sterilant in
hospitals. It is also the principle metabolite of
ethene, a precursor to polyethylene plastics and
other synthetic chemicals. Ethylene oxide can be
measured by gas chromatography in air or
biological specimens. Ethylene oxide reacts in the
body with hemoglobin.
Many food containers for meats, fish,
cheeses, yogurt, foam and clear clamshell
containers, foam and rigid plates, clear bakery
containers, packaging "peanuts," foam packaging,
audio cassette housings, CD cases, disposable
cutlery, and more are made of polystyrene. J. R.
Withey in Environmental Health Perspectives 1976
Investigated styrene and vinyl chloride monomer as
being similar: "Styrene monomer readily migrates
from food contained in it. It makes no difference
whether the food or drink is hot or cold, or contains
fat or water. ...It is not inconceivable that the animal
body behaves as a 'sink' for styrene monomer until
the lipid portion of the animal body either becomes
saturated (although death would probably occur
prior to this event) or the tissues are equilibrated at
the same concentration as the exposure atmosphere.
PVC is used for many products including: flooring,
toys, teethers, clothing, raincoats, shoes, building
products like windows, siding and roofing, hospital
blood bags, IV bags and other medical devices. One
of it's major ingredients is chlorine. When chlorine-
based chemicals are heated in the presence of
hydrocarbons they create dioxin, a known
carcinogen and endocrine disruptor. All PVC
production releases dioxin. Other sources of dioxin
are: production and use of chemicals, such as
herbicides and wood preservatives, oil refining,
burning coal and oil for energy, all car and truck
fig: pyrolysis
Plasticizers are used in PVC that migrate
into a blood recipient via the blood bag, IV bag, IV
tubing. Children's toys are made with pvc.
Anyone who receives blood, is on kidney
dialysis, or has tubes either inserted in them or has
liquid or air transported to their body is at risk.
About 85% of medical waste is incinerated,
accounting for ten percent of all incineration in the
U.S.Approximately five to fifteen percent of
medical waste needs to be incinerated to prevent
infectious disease. The remaining waste, while not
posing any danger from infectious pathogens, is
very dangerous when burned. It contains high
volumes of chlorinated plastics including PVC (also
the toxic substances mercury, arsenic, cadmium and
lead.)
Pyrolysis:
Pyrolysis is a process of thermal
degradation in the absence of oxygen. Plastic &
Rubber waste is continuously treated in a cylindrical
chamber and the pyrolytic gases are condensed in a
specially-designed condenser system.This yields a
hydrocarbon distillate comprising straight and
branched chain aliphatic, cyclic aliphatic and
aromatic hydrocarbons. The resulting mixture is
essentially the equivalent to petroleum distillate.The
plastic / Rubber is pyrolised at 370ºC -420ºC and
the pyrolysisgases are condensed in a series of
condensers to give a low sulphur content distillate.
TYPES OF PYROLYSIS TECHNIQUES:
In our study, we intended to divide pyrolysis into
pyrolysis with the use of catalysts and pyrolysis without the use of
catalysts. Pyrolysis process, which uses catalysts, can take place
in two different kinds of batch reactor
Pyrolysis using expensive catalysts:
Here the catalysts used are metal promoted silica-
alumina or mixtures of metal hydrogenation catalysts with
HZSM-5. The optimization of waste plastic as a function of
temperature in a batch mode reactor gave liquid yields of
about 80% at a furnace temperatures of about 600 degrees
centigrade and one hr residence time. The pyrolysis oil
obtained at the temperature of maximum yield are relatively
heavy in nature. However, hydro processing at relatively low
hydrogen pressures (200-500psiag) at 430-450 degrees
centigrade either thermally or catalytically converts them
into a much lighter product. Sodium carbonate or lime
addition to the hydrolysis and co processing reactors results
into an effective chlorine capture and the chlorine content of
pyrolysis oil reduces to about 50-200ppm and that of the
hydro processed oils to 1-10ppm. The volatile product from
this process is scrubbed and condensed yielding about 10-
15%gas and 75-80% of a relatively heavy oil product.
Pyrolysis using synthesized catalysts from
fly ash:
Table 2 shows chemical compositions of
the catalysts and fly ash obtained from coal fired
power plants. To use fly ash as synthesized catalyst
it was treated in NaOH solution for more 24 hrs,
washed by distilled water and dried. To make other
synthesized catalysts this catalyst can be
impregnated in the nickel nitrate solution. So two
types of catalysts were made for the pyrolysis of PE
and PP of olefin series.
Component Mordent HY
Silica Alumina Fly Ash
SiO2 91.7 74.9
87 53.56
Al2O3 8.23 24.0
13 27.71
Na2O3 0.03 1.1
- 0.37
Fe - 0.03
- 5.53
SiO2/Al2O3 (-)18.9 5.31
6.69 1.93
The setup of the pyrolysis batch reactor is
shown in Figure 1. The mechanical agitator was
installed in the batch type reactor wrapped around
with electric heater for controlling the pyrolysis
temperature of waste plastic. The organic vapor
pyrolyzed from waste plastics can pass the catalytic
cracker bed or not when catalyst is charged with
waste plastics in the reactor. After that, the vapor is
discharged through 1st and 2nd condenser for
product oil conversion. These two condensers are
maintained at different temperatures, 70 and 10.
Pyrolysis oil collected from each condenser was
 analyzed by SIMDIS GC to investigate the catalytic
properties and the pyrolysis conditions. The yields
of pyrolysis oil from polyethylene and
polypropylene were 75 to 89%
Paralysis without the use of catalysts:
The process carried out is the same in this
case also but catalysts are not used. Instead the
temperature parameters are varied.
Commercial technology (CFFLS pyrolysis
technology):
CFFLS (Consortium for fossil fuel
liquefaction science) technology is implemented by
USA.Here; plastic is subjected to a very simple
pretreatment process of shredding of waste to 1-
10cm size. The shredded materials are then
subjected to magnetic and eddy current cleaning
steps. In pyrolysis at about 600 degrees centigrade
CFFLS PYROLYSIS TECHNOLOGY
Plastic waste
Pyrolysis
Cleaning Reactor
oil
for 1hr about 80% of oil yield is obtained,
which is relatively low in chlorine content (10ppm).
Future prospects of pyrolysis technology:
Paralysis is a very promising and reliable
technology for the chemical recycling of plastic
wastes. Countries like UK, USA, and Germany etc
have successfully implemented this technology and
commercial production of monomers using
pyrolysis has already begun there.
Paralysis offers a great hope in generating
fuel oils, which are heavily priced now. This reduces
the economical burden on developing countries. The
capital cost required to invest on pyrolysis plant is
low compared to other technologies. So, this
technology may be the beacon light in the future to
a world, which is now on the verge of acute fuel
shortage.
Indian scenario and conclusion:
According to one estimate in India about
80000 tons of municipal solid waste is generated
everyday of which plastics comprise of only 4-6%.
A scientific and systematic approach in recycling
the plastic waste in India is still in its infancy.
Unscientific and haphazard landfilling is in
operation in urban areas and in rural areas
practically there is absence of any treatment.
The reasons are many. Both the
government and private industrial sectors failed to
initialize the development of indigenous
technologies related to this area. Except well-
established industries like Reliance polymers etc,
others are not investing in a venture like this.
Nevertheless, India has already taken its
first step in this direction. In
the course of time, with the potential that our
country has, India will surely make the most of
chemical recycling methods and achieve great
profits and progress by adapting pyrolysis.
Random Depolymerization:
Plastics have become an integral part and
parcel of our lives due to its economic value, easy
availability, easy processability, light-weight,
durability and energy efficiency, besides other
benefits.
Since plastics are re-usable and
recyclable, there should not have been any problem
of disposal of the plastics waste, however due to our
poor littering habits and inadequate waste
management system/infrastructure, plastics waste
management, disposal continues to be a major
problem for the civic authorities, especially in the
urban areas.
Though various steps have already been
either taken or initiated by the Government and the
legal/civic authorities to reduce the problem of this
waste management, an innovative invention by Prof.
Alka Umesh Zadgaonkar of the Department of
Applied Chemistry, G.H. Raisoni College of
Engineering, Nagpur, Maharashtra, has created a
hope and scope to tackle this problem more easily
and more environmentally-friendly manner.
 She has invented a catalyst system, which
converts polymeric materials into liquid, solid and
gaseous fuels.
The Process:
Under controlled reaction conditions, plastics
materials undergo random de-polymerization and
are converted into three products:
a) Solid Fuel – Coke
b) Liquid Fuel – Combination of
Gasoline, Kerosene, Diesel and Lube Oil
c) Gaseous Fuel – LPG range gas
The process consists of two steps:
i) Random de-polymerization
- Loading of waste plastics into the
reactor along with the Catalyst system.
- Random de-polymerization of the waste
plastics.
ii) Fractional Distillation
- Separation of various liquid fuels by
virtue of the difference in their boiling points.
One important factor of the quality of the
liquid fuel is that the sulphur content is less than
0.002 ppm – which is much lower than the level
found in regular fuel.
Fig. 2
10%
Bags Films
etc.
Others
45% 45%
Bottles &
Containers
Fig: process of fuels
Principals Involved:
All plastics are polymers mostly
containing carbon and hydrogen and few other
elements like chlorine, nitrogen, etc. Polymers are
made up of small molecules, called monomers,
which combine together and form large molecules,
called polymers.
When this long chain of polymers breaks
at certain points, or when lower molecular weight
fractions are formed, this is termed as degradation
of polymers. This is reverse of polymerization or
de-polymerization.
If such breaking of long polymeric chain
or scission of bonds occurs randomly, it is called
‘Random depolymerization’. Here the polymer
degrades to lower molecular fragments.
In the process of conversion of waste
plastics into fuels, random depolymerization is
carried out in a specially designed reactor in the
absence of oxygen and in the presence of coal and
certain catalytic additives. The maximum reaction
temperature is 350oC. There is total conversion of
waste plastics into value-added fuel products.
Unique features of the process and product
obtained are:
1. All types of Plastics Waste including CD’s and
Floppies having metal inserts, laminated plastics –
can be used in the process without any cleaning
operation. Inputs should be dry.
2. Bio-medical plastics waste can be used.
About 1 liter of Fuel is produced from 1 kg of
Plastics Waste. Bye-products are Coke and LPG
Gaseous Fuel.
3. Any possible dioxin formation is ruled out during
the reaction involving PPVC waste, due to the fact
that the reaction is carried out in absence of oxygen,
a prime requirement for dioxin formation.
4. This is a unique process in which 100% waste is
converted into 100% value-added products.
The process does not create any pollution.
Though the fuel so produced from the
plastics waste could be used for running a four-
stroke/100 cc motorcycle at a higher mileage rate,
the inventor agrees that separation of petrol from the
liquid fuel could be a complex generation.
Nevertheless the product is good enough for use as
an alternative clean fuel in boilers and other heating
systems.
It is, however, not the first time that fuel
has been produced out of plastics waste. A Japanese
company, M/s. Osmotic, is already manufacturing
fuel out of plastics waste at an industrial plant in
Japan employing the Pyrolysis process. However,
Prof. Zadgaonkar’s process is a continuous one and
hence is cheaper, whereas the Japanese technology
is a batch process and is comparatively costlier.
A live demonstration of the production of
Liquid Fuel was made in the presence of ICPE led
team in the laboratory. Three kgs of plastics scrap
was used to produce about 2 litres of Liquid Fuel in
about 3 hrs. The reaction was terminated after the
trial demo. The fuel obtained was used in smooth
running of a motorcycle, which was experienced by
the visiting members. However, the inventor does
not wish to claim the product as a substitute for
Petrol or Diesel at this stage. The present use would
be as a fuel for running boilers and other heating
purposes.
Zadgaonkars’ Process:
The process is also carried out in absence of oxygen
& in the presence of coal and certain hybrid
catalytic additive.The reaction parameters viz.
temperature and pressure for a batch were
extremely high in initial stages. Later with the use
of hybrid catalyst the maximum reaction
temperature were brought down to a greater extend.
Steps Involved:
1. Feed System
2. Premaster
3. Melter
4. Dechlorination
 Here complex hydrocarbons break into simpler
5. Reactor molecules to increase the quality and quantity of
1. Feed System: lighter, more desirable products.
It is also known as unzipping reaction.

Fig: feed system

Feed consists of all type of plastic scrap
The system essentially consist sorters and sizing
equipment like of Crusher
The material is crushed in to uniform size for ease
of handling and melting
This process of sizing and grading the waste is semi
automatic.

2. Pre-melting/Feeder:
The feeder consists of a driving motor,
electric heater and control panel.
The granular crushed/cut/shredded waste plastic
melts and injected in the melting vessel.
Fig: reactor section
3. Melter: Advantages:
In melter vessel, the feed is heated to  Reduces pollution helps in waste
275⁰C -410⁰C. plastic degradation.
The heat required for the melting will be supplied  Cheaper and quality fuel.
by the gas generated from the plant.  Perfect solution for waste plastic,
rubber, tyre management.
4. Dechlorination:  Raw material readily available.
 Plant is energy self sufficient.
The molten plastic will be drawn from the
overflow end of melter vessel to Dechlorinate.
Here the waste plastic is heated with catalytic
additive which helps in removal of chlorine.
The hydrocarbons free from HCl shall be used for
heating purpose
The molten plastic is taken out and subjected to
depolymerization

5. Reactor Section:
The molten waste plastic free of chlorine is allowed
to flow over a heated surface at 300 - 350 OC
polymers are highly heat sensitive due to the limited
strength of the covalent bonds
Hence The breaking of chemical bonds under the
influence of heat occurs
Conclusion:
This study shows without doubt that one-way PET
bottles are as ‘ecologically favourable’ as refillable
glass under non-deposit circumstances. A plausible
alternative could be to revise the Packaging
Ordinance, such that ecologically favourable
packaging systems would be included in a deposit
without being discriminated when compared to
refillable packaging. It cannot be explained to
consumers that they should return the empty bottles
to the store if they are
subsequently transported to the other side of the
world for recycling. This way we are losing
environmental gain that is the prime reason behind
bottles collection. This study has shown that it does
not matter whether collected PET is recycled into
polyester fibre, sheet, strapping or back into PET
bottles: they all offer equal benefits to the ecological
profile of PET. Mandatory or semi mandatory
requirements to recycle PET bottles into PET bottles
would be ridiculous. Public perception does not
always match reality. Not many people comprehend
that PET bottles, even for single use, are as good as
their glass counterparts. This calls for further
improvements in balanced, reputable education, and
independent and irrespective of local political

Reference
 http://www.sciencedirect.com/science
 http://biodegradableplastics.wordpress.co
m/2008/04/15/fuel-from-plastic-waste/
 http://www.indiacar.com/infobank/Plastic
_fuel.asp
 http://www.tradekey.com/selloffer_view/i
d/828854.htm