How to turn plastic waste into diesel fuel cheaply

[AAS]

new project

Thank you beyond biodiesel, I'm hoping the stirrer will somewhat compensate and at least distribute the heat uniformly internally. More contact exposure and from the bottom makes sense, will use that in next prototype, cost and simplicity of building made me opt for the existing arrangement of elements.

The furnace ways about 2 tons and reactor about 500kg's so now that it's in position, it's staying there for now.

Regards
AAS

[Beyond Biodiesel]

Welcome AAS, looks like you have been busy, and made one of the best pyrolysis units posted here so far. The only recommendation I have is more uniform heating tends to increase heating rate which increases throughput. So, instead of turning off heating elements reduce the power going to each heating element by either wiring them in series or using several variacs, one for each heating wire, will allow you to reduce the watt density easily, so that you can spread those watts uniformly. Also, a hot plate at the bottom in the form of a coil of nichrome wire under your retort will spread those watts more uniformly while increasing the heating rate.

[AAS]

new project

Post production fuel will be purified using a pabiodiesel 120 inverted centrifuge.

[SlyviaCoryell]

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[AAS]

new project

Only S/Steel used, minimum thickness of 10mm used on the lid, mechanical seals everywhere, pressure gauge installed, will be running at 400degrees.

Kind Regards

[AAS]

new project

I would like to give some figures and would like to know how it sounds

Capacity of reactor is 900L, think I will get about 450kg of shredded mixed plastic mostly PE, or a mix of WMO and shredded plastic about 500kg

Energy used to heat reactor is 3phase electricity, total capacity of oven is 45kw, but presently only using 30kw (only using bottom 6 0f the 9 X 5Kw elements to start)

Dual condensers: primary is straight rods between reactor and storage tank/trap

Secondary condensor is the top third part of storage tank consisting of internal looped and cooled pipes positioned between metal flakes suspended between two metal grids.

Planning to make one combined fraction in the diesel range, depending on the specific density of the product I will insulate the reflux if needed.

Catalyst will be a locally sourced zeolite mixed into the wet batch.

Regards
AAS

[AAS]

new project

Hi guys.
Been reading the blog for the last year or so, slowly building my plant, almost done. I'm from South Africa. I studies polymer science up to a masters degree in the in the early 2000's.

Added a view pics, will be running my first run in a week or so, will post results.

Kind Regards

[rozier56]

Some clarification on terms used.
1.Distillation column: Tower with maybe a few baffels inserted and gas sent to condenser which is normally water or air cooled.
2.Fractionation column: Tower with plates at different heights/temps to remove distillate according to requirements of the products required.
3. Reflux column: Tower with baffels inserted,gas is then either returned to a point in this column,or passed through condenser and then returned to reflux column.
I note some folks talk about reflux columns, but their pic's don't show this.It is slightly confusing.

[Excalibur]

Babataku
Antioxidant tipped a few years ago. I haven't tried or heard of anyone using it.

Refux temperatures. The way I see it is:
...if temps are too high, there could be a wax problem or the fuel may be too heavy.
...if temps are too low, the fuel will be too light. Also making it will use up more energy.
So there is a "window" of temperature range that you need to find to suit your retort machine and feedstock. Once you get within this range, a small amount of trial&error is required to find the "sweet spot".

Re cooling of the reflux. I wondered if air cooling of the reflux vessel would help control temperature downward. The thought was to weld fins on, like motorcycle barrel fins. Then blow air across the fins at a velocity that stabilized temperature at the target. A variable speed fan would allow control of the cool rate.
Disclaimer, I haven't tried this exact remedy)

[Babataku]

Thanks Excalibur,

I intend to hold the reflux at about 220deg celc, i am not sure whether heating the reflux is neccessary, or the vapour heat will be enough with insulation? my worry is that if the reflux exceeds this temp, how will i cool it down back to 220deg??

Will be posting pictures this week, all materials should be with me tomorrow and i will start piecing it together.

What about storage issues?? i am a bit worried...will i have to look for some Anti-oxidants?

[Excalibur]

2. From my reading, PP derived fuel is non waxing whilst PE turns into Wax after production? i have option of getting waste PP or PE, which is better?
.

If PE or any plastic is turning to wax, then it's not getting refluxed sufficiently and subsequently not cracked enough. Compared to WMO you'd need to "forcibly crack it down much harder". To cure waxing, adjust reflux temperature downward.

Looking forward to some photos...

[Babataku]

I had thought of doing the same thing, and using Excalibur's idea of combining this method with continuous feed might be the solution to the problem of continuous feed plastic pyrolysis.



Cracked fuels are known for polymerization, so storage life is not likely to be good for the fuel.

Color is a function of how well your pyrolysis unit is designed, because improved color has to do with reducing boil-over.

Thanks for the replies...A few more questions though:

1. What catalyst can i use to avoid polymerization? Clay? Ash from fire place?? Kitty Litter? i have these readily available and at reasonable price? i want to keep the produced fuel stored for maximum of 20 - 30 days only
2. From my reading, PP derived fuel is non waxing whilst PE turns into Wax after production? i have option of getting waste PP or PE, which is better?

All i want is to produce a gold clear color fuel which can be kept for 20 -30 days max. it will be used to fire a diesel boiler only.

[Beyond Biodiesel]

Hi All,

I am busy building a new unit to process waste plastics. i have been processing WMO for a while and need to try plastics on a more bigger and commercial scale. Plastic waste, i can get at a cheaper price.

The unit will be 500Ltr tank capacity, fired by a diesel burner. i will have a reflux column on top heated to about 300deg celc, and i will have one water cooled condenser to about 80deg celc, as i only want fuel to use in diesel boiler. so quality should be OK. from there i will have a 25ltr Bubbler/flame arrest tank and then all excess gas will be burner off.

My challenge is how to maximize the tank capacity..im thinking of heating maybe 100Ltrs of WMO to about 150deg celc hold it there, and then start adding the waste plastic chunks which should melt instantly at those temps, im guessing i can add about 250Kg of waste plastic chunks and then there after i will raise the temp to 400deg celc. My assumption is based on plastic density of 1kg:1.4Ltrs so in total after melting i will have about 450Ltr of molten plastic & WMO mix...which should in turn give me about 340Ltrs of distillate. i have thought of any catalyst to use.

Has anyone tried this method?? Any comments?

I had thought of doing the same thing, and using Excalibur's idea of combining this method with continuous feed might be the solution to the problem of continuous feed plastic pyrolysis.

Also if i use PP what quality can i expect in terms of color and storage issues, can i store it for 30 or more days without any additives?

i will be posting pictures soon.

Cracked fuels are known for polymerization, so storage life is not likely to be good for the fuel.

Color is a function of how well your pyrolysis unit is designed, because improved color has to do with reducing boil-over.

[Excalibur]

Sounds good. The WMO/molten plastic blend would be able to be moved with some kind of slurry pump that's rated for those temperatures. A small reservoir of hot WMO could used to flush as required. Just bouncing ideas around...

[Babataku]

2nd Generation Pyro Plant

Hi All,

I am busy building a new unit to process waste plastics. i have been processing WMO for a while and need to try plastics on a more bigger and commercial scale. Plastic waste, i can get at a cheaper price.

The unit will be 500Ltr tank capacity, fired by a diesel burner. i will have a reflux column on top heated to about 300deg celc, and i will have one water cooled condenser to about 80deg celc, as i only want fuel to use in diesel boiler. so quality should be OK. from there i will have a 25ltr Bubbler/flame arrest tank and then all excess gas will be burner off.

My challenge is how to maximize the tank capacity..im thinking of heating maybe 100Ltrs of WMO to about 150deg celc hold it there, and then start adding the waste plastic chunks which should melt instantly at those temps, im guessing i can add about 250Kg of waste plastic chunks and then there after i will raise the temp to 400deg celc. My assumption is based on plastic density of 1kg:1.4Ltrs so in total after melting i will have about 450Ltr of molten plastic & WMO mix...which should in turn give me about 340Ltrs of distillate. i have thought of any catalyst to use.

Has anyone tried this method?? Any comments? Also if i use PP what quality can i expect in terms of color and storage issues, can i store it for 30 or more days without any additives?

i will be posting pictures soon.