Windsol since from its inception is committed to green energy development and

have promoted products with new technologies. Conversion of plastic to fuel is

already an established technology in Japan ,US,& Germany and still being
further refined for better results. WASHINGTON (May 16, 2017) – Argonne
National Laboratory (ANL), part of the U.S. Department of Energy, has
determined that using Pyrolysis to convert non-recycled plastics into ultra-low-
sulphur diesel (ULSD) fuel results in significant energy and environmental
benefits. These include reductions of up to 14 percent in greenhouse gas
emissions, up to 58 percent in water consumption, and up to 96 percent in
traditional energy use when compared to ULSD from conventional crude oil.

After studying various technologies available in the market we have designed a

process in which waste heat is recycled thereby reducing the energy
requirement of the process. Size of plant is reduced with high yield. There is
Zero process waste and nothing goes to environment, resulting pollution free
process.
PRESENT SITUTAION

As per data available of 2017, India produces 15000 Tons of waste plastic daily.
Disposal of this huge ever growing waste stock is a serious concern to
authorities. Countries like Japan, Germany and the United States have already
implemented the plastic to fuel conversion process with much success. These
three countries have also been successful in creating business models out of the
conversion process, resulting in the conversion model becoming a socially
workable business preposition.

UNDERSTANDING PLASTIC

We must understand plastic, before we approach to its disposal techniques.

Plastics constitutes in two main categories. It is Thermoplastics and Thermoset
plastics. Thermoplastics make up 80% of the plastics and Thermoset plastics
make up of remaining 20 % of plastics produced today. Thermo plastics can re-
melt or re-mould and therefore it is recyclable easily but Thermoset plastics
cannot re-melt or reshape and therefore it is difficult to recycle.
 Type of Plastics as raw materials and its contents

Type of plastics Contents

PE (HDPE, LDPE), PP, PS
PET, PVA, PF
PVC, PVCD
Nylon (polyamide), PU
Polyphenylene sulphide
Hydro carbons
Hydro carbons with oxygen
Hydrocarbons with chlorine
Hydrocarbons with nitrogen
Hydrocarbons with sulphur

Effect of plastics in production.

Type of plastics Product

PET Terephthalic acid and benzoic acid
PVA Water and alcohol
PVC, PVDC HCL Gas and carbonous compound
PU, PF, NYLON Carbonous product
PE, PS, PP Liquid fuels

Uses of different types of plastics.

Type of Plastics Uses

Polyester Textile fibre
PET Carbonated drink bottles, Plastics film
PE Supermarket bags, Plastics bottle
HDPE Milk jugs, Detergent bottles, Thicker Plastics film, Pipes
LDPE Floor tiles, Shower curtains, Cling film
PVC Agriculture (fountain) pipe, Guttering Pipe, Window
frames & Sheets for Building material foam use for insulation of roofs and
walls, disposal cups, plates, food Container, CD and cassette box.
PP Bottle caps, Drinking straws, Bumper, House ware,
Fibercarpet, rope
Plastic has been known as product of millennium and consumption of plastic is
growing at the rate of 9% globally .In India this rate is more due to the socio
economic conditions. Plastic waste management is becoming is very essential to
manage the waste plastic generated.

Plastics Recycling Technologies

There are different types of technology based process to recycle plastic:-

1. Mechanical Recycling- Recycling of plastics waste into reusable product.

2. Chemical Recycling – Gasification, blast furnace

3. Incineration- Burning of waste plastics to obtain energy.

4. Pyrolysis – Conversion of waste plastics into liquid fuels.

In India the first 3 options are being used since long but it is found that all of them
contribute to environment pollution, even waste plastic processing through cement
kiln or road making, results pollution. Toxic gases are generated while melting in the
combustion chamber. Putting the plastics in roads does not make plastics disappear.
They are merely hiding. Over time, as the road weathers, the plastic too breaks
down into micro particles of plastic and enter the environment.

Conversion of waste plastic into fuel is better option as compared to any available
technologies.
Above is 100 ton waste plastic processing plant layout with 60000 LT Plastic fuel oil
(PFO) output. In developing countries plastic is manufactured with high calcium
dosing .Due to this impurity the oil output is low as compared to developed countries.

3 Ton waste plastic processing plant with a oil output of 1800 litre per day
Advantages of waste plastic to fuel:

01. It completely transforms plastic to another product. So no further recycling is

possible. Problem of disposal is eliminated.

02. Conversion of waste is in high value fuel.

03. There no pollution since no gas is released in environment or any waste is

disposed. It is almost Zero waste process.

O4.Contributes towards fuel requirement of energy thereby reducing import of oil.

05. Fuel generated is with very low sulphur content thereby reducing pollution during
burning.

06. Energy needs of the process is very less since waste heat is reused.

07. The bitumen char produced as bye product is also used in boiler with coal or can
be used in road making.

Usage of Plastic Fuel Oil and by products

Product Use

PFO As an Industrial Fuel

Carbon Black As a fuel in boiler/furnace/cement Plant

Pyrolysis Gas Reused to heat plastic oil reactor.

PRE CONDITIONS FOR SUCCESSFUL INSTALLATION &
IMPLEMENTATIO OF WASTE PLASTIC TO OIL PROJECT

Waste Plastic availability, continues flow with minimum impurity will result in
better the Oil output ratio .Coordination with municipality, waste collecting
agencies is essential for success of this project. Technology is now at the stage
where the techno commercial viability is possible & hence management and
coordination between various agencies is the only critical factor.

01.Approval & consent from government to install & operate waste plastic
processing unit in the vicinity of waste processing plant in coordination
with waste collecting agency. A commercial arrangement will be
mutually bonding & profitable preposition.
02.Proper pollution and fire safety approvals and arrangement has to be
done. Since both the raw material and finished product is fire prone,
investment on this must be done on high priority.
03.Manpower safety and health care will be under watch continuously. A tie-
up with NGO will be a better option and will contribute towards CSR
activity.
04. A proper laboratory set up to test the raw material and PFO should be
installed. A tie up with government approved lab will add value to the
project.
05.Packaging, transportation of finished product is also a factor to be taken
seriously.
06.Technology up gradation, provision of expansion in capacity should be
accounted in project working. Additional space and raw material supplier
should be on records for future expansion.
07.At present sale of PFO is allowed to end user only therefore a routine
visits should be done at client work place to ascertain proper usage of oil.
 Commercial Calculation of 3 TON Processing Plant

A. Raw Material is considered @ 4 /Kg including processing charges

B. Plant Capacity 3000 Kg per day with 60% output (1800 LT)

C. Conversion Charges including Raw material, Labour charges, Energy

charges water expenses and other expenses amounting to Rs.15 per Kg.

D. Project Cost considered Rs. 2 Cr. Without land & Building.

SALE: Rs.22410000.00

OIL 1800 LT X 30 Days X 10 Months X Rs.40 = Rs.21600000.00

Carbon Black: 300 Kg X 30 Days X 10 Months X Rs.9= Rs.810000.00

INTEREST @ 10.5% on Rs.2 Cr. = Rs.2100000.00

Conversion Cost: 3000 Kg X30 Days X10 Months X Rs.15=Rs.13500000.

Annual Return Rs.22410000.00 –Rs.13500000.00 = Rs.8910000.00

Less: Interest Rs.2100000.00 =Rs.6810000.00

Return on investment: Period: 3 Years.

Above Calculations are estimated data for reference only