A

Project Report
On

” A Review on Various Techniques used for Plastic Waste to Energy Conversion”

Submitted to
Dr. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW
In
Partial Fulfilment of the Requirements for the degree of
BACHELOR OF TECHNOLOGY
In
CHEMICAL ENGINEERING

Submitted By:

Abdul Ahmad (Roll No. 1504351002)

Abhay Pratap Singh (Roll No. 1504351003)
Anshumaan Singh Pundir (Roll No. 1504351007)
Shubham Agrawal (Roll No. 1504351022)

Under the Guidance of:

Er. Ravindra Kumar
DEPARTMENT OF CHEMICAL ENGINEERING
BUNDELKHAND INSTITUTE OF ENGINEERING AND TECHNOLOGY
JHANSI-284128 (U.P.)
SESSION 2018-19
 BUNDELKHAND INSTITUTE OF ENGINEERING AND TECHNOLOGY,
JHANSI(U.P.)
Department Of Chemical Engineering

CERTIFICATE

This is to be certified that the project titled “A Review on Various Techniques used for
Plastic Waste to Energy Conversion” has been delivered by Abdul Ahmad, Abhay Pratap
Singh, Anshumaan Singh Pundir and Shubham Agrawal the student of Chemical
Engineering under my guidance and supervision in the partial fulfillment of the Bachelor’s
degree in Chemical Engineering from “Bundelkhand Institute of Engineering and
Technology Jhansi” during the academic year 2018-19.

Dr. Hiwarkar Ajay Devidas Er. Ravindra Kumar

Designation: Head of the department Designation: Assistant Professor

Chemical Engineering Department Chemical Engineering Department
B.I.E.T Jhansi B.I.E.T Jhansi

i
 ACKNOWLEDGEMENT

For the successful accomplishment of our project, we would like to thank Almighty for his
blessings. A Sincere thanks to our final year project guide, Er. Ravindra Kumar (Assistant
Professor) Department of Chemical Engineering, BIET JHANSI, whose help, stimulating
suggestions and encouragement, helped us to coordinate our project especially in writing this
report. It has been great pleasure for us to our work under his guidance.
We are highly thankful to Dr. Hiwarkar Ajay Devidas (Head of the Department), Dr. Sudeep
Yadav (Asst. Professor), Dr. Tej Pratap Singh (Assistant Professor), Dr. Manju Verma
(Assistant Professor), Er. Om Agnihotri (Assistant Professor), Er. Swasti Medha (Assistant
Professor) and all the staffs of Department of Chemical Engineering, B.I.E.T JHANSI for their
full cooperation in providing necessary facilities, environment needed for the work.
Finally, we wish to express our modest and sincere regard to our parents and friends for their
intensive support and encouragement for this Project work.

Thanking You.

Abdul Ahmad (1504351002)

Abhay Pratap Singh (1504351003)
Anshumaan Singh Pundir (1504351007)
Shubham Agarwal (1504351022)

ii
 ABSTRACT

Polymers are finding extensive application in our day to day life. The low density, high strength
to weight ratio, ease of processing etc. make them attractive over other conventional materials.
The various fields of applications of polymers include different sectors such as structural and
non-structural, automobile, medical, aerospace etc. Extensive use results in accumulation of
waste plastics. The safe disposal of waste plastics is a major problem faced by the polymer
industry. The combustion of polymers can release so many toxic gases to the atmosphere and
can lead to major environmental hazards. Since crude oil is the starting material to produce
plastics, the reverse processing of plastics back to crude oil is an innovative method for better
disposal of plastics.
Waste plastics are heated in an inert atmosphere. The waste plastics used include, Polyethylene
(PE), Polypropylene (PP), and Polystyrene (PS). We studied about various plastic waste to
energy conversion techniques, their advantages, disadvantages and comparison.
In incineration method, the plastic waste is burned, and the heat is utilized. This method has
advantage that it requires less effort and less infrastructure however it causes harmful air-
pollution.
Gasification involves thermal conversion of a plastic material with a small amount of air or
oxygen, into a mixture of combustible gases called syngas. Gasification is a safer way of
eliminating biohazardous waste and has a far less negative impact on the environment than
incineration. Also, an important benefit of gasification is the creation of syngas, a renewable
energy source.
Pyrolysis is the controlled burning or heating of plastic material in the absence of oxygen. The
product formed from the pyrolysis process are oil, syn gas, char. Pyrolysis has advantage over
other techniques that it has higher yield however it has higher initial and operational cost.
We have compared various thermochemical conversion processes (incineration, gasification ,
pyrolysis) of plastic waste to energy conversion on the basis of their product, catalyst used,
calorific value, uses, their advantages and disadvantages ,etc.

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 CONTENTS

CHAPTER TITLE PAGE NO

• Certificate i
• Acknowledgement ii
• Abstract iii
• Contents iv
• List of Figures v
1 Introduction 1
2 Plastics 2
2.1. Classification of polymers 3
2.2. Type of Plastics 10
2.3. Advantages of Plastics 22
2.4. Disadvantages of Plastics 22
2.5. Consumption of Plastics and Generation of Plastic wastes 23
3 Plastic wastes 26
3.1. Municipal Solid wastes 26
3.2. Industrial Plastic wastes 28
3.3 Problems arising in disposal of Plastic Wastes 29
4 Concept of 4R´s 30
5 Various Plastic Waste Management Technique 33
5.1. Landfilling 34
5.2. Mechanical Recycling 36
5.3. Biological Recycling 38
6 Thermo chemical Recycling 40
6.1. Incineration 41
6.2. Gasification 43
6.3. Pyrolysis 46
6.4. Comparing Incineration, gasification and pyrolysis 52
7 Conclusion 53
8 Future aspects of Plastic Waste to energy 54
References 55
 LIST OF FIGURES

Fig. no. Figure name Page no.

2.1 Structure of polymer 4

2.2 Polyethylene terephthalate 11

2.3 HDPE Pipes for Water Supply 12

2.4 Plastic packing film 13

2.5 LDPE shopping bag 14

2.6 Polypropylene plastic measuring jug 15

Properties

2.7 Polystyrene foam sheet 16

2.8 Phenol formaldehyde resin 18

2.9 Urea-formaldehyde adhesives 19

2.10 Melamine formaldehyde plates 20

2.11 Epoxy resin adhesives 21

2.12 Global Plastic Production 23

2.13 Waste generation in India 24

3.1 Sources of municipal plastic waste 27

3.2 Sources of Industrial Waste from - 28

- various industries

4.1 Showing symbol of 4R 31

4.2 Recycle code of plastics 32

5.1 Landfilling 35

5.2 Flowsheet of Mechanical Recycling 37

5.3 Cycle of Biological Recycling 39

6.1 Flowsheet explaining Incineration processes 42

6.2 Flowsheet explaining gasification 44

6.3 Block diagram of Pyrolysis waste to valuable products. 47

6.4 Thermal Pyrolysis setup 48

6.5 Catalytic Pyrolysis Flowsheet 49

v
CHAPTER 1

INTRODUCTION

Plastic plays a vital role in improving the standard lives of human being from decades. Plastic
was invented in 1860. These are light, durable, modifiable and hygienic. These are made of
long chain molecules called Polymers and polymers are made from naturally occurring
substances like crude oil or petroleum. These polymers can be made into granules, powders
and liquids, becoming raw materials for plastic products.
Plastic is a key of innovation of many products in various sectors such as construction,
healthcare, electronic, automotive, packaging etc.

The demand of plastics has been increased due to the rapid growth of the world population.
The use of plastics is associated with significant environmental problems due to their
continuous accumulation in landfills, because plastic waste does not degrade or degrades at a
very low pace.

Due to the depletion of fossil fuel resources such as crude oil, natural gas, and coal, the
present rate of economic growth is unsustainable. Therefore, many sources of renewable
energy have been exploited, but the potentials of some other sources such as plastics waste
are yet to be fully developed as full-scale economic activity.

Development and modernization have brought a huge increase in the production of plastic
commodities. This directly or indirectly generates waste due to their wide range of
applications, their versatility of types and relatively low cost.

1
The plastics are mostly non-biodegradable and thus remain in the environment for hundreds
of years. Conventional recycling methods such as sorting and grinding can recycle only about
15-20% of total plastic waste.

The energy recovery technologies such as thermal and catalytic pyrolysis, gasification and
plasma arc gasification are receiving more attention nowadays as alternative plastic waste
recycling methods.

Pyrolysis process converts plastic waste into liquid oil, solid residue (char) and gases at high
temperatures (300-900°C) via thermal decomposition. However, there are certain limitations
in the conventional thermal pyrolysis, where the whole process is temperature-dependent.

The liquid oil produced from thermal pyrolysis may contain impurities like residues, chlorine,
and Sulphur. Moreover, the thermal pyrolysis of PE type plastics such as HDPE and LDPE
along with PP are difficult to conduct due to their crossed chain hydrocarbon structures.

2
 History of Plastics
From a historical viewpoint, the development of plastics can be regarded as one of the most
important technical achievements of the twentieth century. In just 50 years plastics have
permeated virtually every aspect of daily life, paving the way for new inventions and
replacing materials in many existing products.

The success of these products is based on their properties of resilience, resistance to moisture,
chemicals and photo biodegradation, their stability and the fact, that they can be molded into
any desired form.

The original breakthrough for the first semi-synthetic plastic material - cellulose nitrate,
occurred in the late 1850’s and involved the modification of cellulose fibers with nitric acid.
Cellulose nitrate had many false starts following its invention by Alexander Parkes, who
exhibited it as the world’s first plastic in 1862.[1]

The world’s first plastic was reproduced at the turn of the twentieth century and was based
mainly on natural raw materials. Only in 1930 were thermoplastics, made from the basic
materials styrene, vinyl chlorine and ethylene, introduced onto the market.

However, the main growth of the plastics industry did not take place before the 1960’s,
reaching production of over 40 million ton per year in 1973. Following a temporary drop in
production during the oil crises and the economic recession in the beginning of the 1980’s,
the world production of plastics continued to increase to approximately 77 million ton in
1986, and 86 million ton in 1990.[1]

3
CHAPTER 2

PLASTICS
Polymers in the presence of suitable catalyst, are broken into monomers such as
ethylene, propylene, vinyl, styrene and benzene. These monomers are then chemically
polymerized into different categories of plastics.[1]

The word “Polymer” is derived from two Greek words, ‘Poly’ that means many (numerous)
and ‘Mer’ which means units. In basic terms, a polymer is a long-chain molecule that is
composed of a large number of repeating units of identical structure. These identical
structures, we understand as a unit made up of two or more molecules, join together to form a
long chain. [2]

Fig. 2.1 Structure of polymer [3]

4
 2.1 Classification of Polymers [3]

Since Polymers are numerous in number with different behaviors and can be naturally found
or synthetically created, they can be classified in various ways. The following are some basic
ways in which we classify polymers. [3]

Classification Based on Source

The first classification of polymers is based on their source of origin.

(i) Natural polymers:

The easiest way to classify polymers is their source of origin. Natural polymers are polymers
which occur in nature and are existing in natural sources like plants and animals. Some
common examples are Proteins (which are found in humans and animals), Cellulose and
Starch (which are found in plants) or Rubber (which we harvest from the latex of a tropical
plant).

5
(ii) Synthetic polymers:

Synthetic polymers are polymers which humans can artificially create/synthesize in a lab.
These are commercially produced by industries for human necessities. Some commonly
produced polymers which we use day to day are Polyethylene (a mass-produced plastic
which we use in packaging) or Nylon Fibers (commonly used in our clothes, fishing nets etc.)

(iii) Semi-Synthetic polymers:

Semi-Synthetic polymers are polymers obtained by making modification in natural polymers

artificially in a lab. These polymers formed by chemical reaction (in a controlled
environment) and are of commercial importance. Example: Vulcanized Rubber ( Sulphur is
used in cross bonding the polymer chains found in natural rubber) Cellulose acetate (rayon)
etc.

Classification Based on Structure of Polymers

Classification of polymers based on their structure can be of three types:

(i) Linear polymers:

These polymers are similar in structure to a long straight chain which identical links
connected to each other. The monomers in these are linked together to form a long chain.
These polymers have high melting points and are of higher density. A common example of
this is PVC (Poly-vinyl chloride). This polymer is largely used for making electric cables and
pipes.

(ii) Branch chain polymers:

As the title describes, the structure of these polymers is like branches originating at random
points from a single linear chain. Monomers join together to form a long straight chain with
some branched chains of different lengths. As a result of these branches, the polymers are not
closely packed together. They are of low density having low melting points. Low-density
polyethene (LDPE) used in plastic bags and general-purpose containers is a common
example.

6
(iii) Crosslinked or Network polymers:

In this type of polymers, monomers are linked together to form a three-dimensional network.
The monomers contain strong covalent bonds as they are composed of bi-functional and tri-
functional in nature. These polymers are brittle and hard. Ex: - Bakelite (used in electrical
insulators), Melamine etc.

Based on Mode of Polymerization

Polymerization is the process by which monomer molecules are reacted together in a

chemical reaction to form a polymer chain (or three-dimensional networks). Based on the
type of polymerization, polymers can be classified as:

i) Addition polymers:

These types of polymers are formed by the repeated addition of monomer molecules. The
polymer is formed by polymerization of monomers with double or triple bonds (unsaturated
compounds). Note, in this process, there is no elimination of small molecules like water or
alcohol etc. (no by-product of the process). Addition polymers always have their empirical
formulas same as their monomers. Example: ethene n(CH2=CH2) to polyethene -(CH2-
CH2)n-.

ii) Condensation polymers:

These polymers are formed by the combination of monomers, with the elimination of small
molecules like water, alcohol etc. The monomers in these types of condensation reactions are
bi-functional or tri-functional in nature. A common example is the polymerization of
Hexamethylenediamine and adipic acid. to give Nylon – 66, where molecules of water are
eliminated in the process.

7
Classification Based on Molecular Forces

Intramolecular forces are the forces that hold atoms together within a molecule. In Polymers,
strong covalent bonds join atoms to each other in individual polymer molecules.
Intermolecular forces (between the molecules) attract polymer molecules towards each other.

Note that the properties exhibited by solid materials like polymers depend largely on the
strength of the forces between these molecules. Using this, Polymers can be classified into 4
types:

i) Elastomers:

Elastomers are rubber-like solid polymers, which are elastic in nature. When we say elastic,
we basically mean that the polymer can be easily stretched by applying a little force.

The most common example of this can be seen in rubber bands (or hair bands). Applying a
little stress elongates the band. The polymer chains are held by the weakest intermolecular
forces, hence allowing the polymer to stretch. But as you notice removing that stress also
results in the rubber band taking up its original form. This happens as we introduce crosslinks
between the polymer chains which help it in retracting to its original position and taking its
original form. Our car tyres are made of Vulcanized rubber. This is when we introduce
sulphur to cross bond the polymer chains.

ii) Thermoplastics:

Thermoplastic polymers are long-chain polymers in which inter-molecules forces (Van der
Waal’s forces) hold the polymer chains together. These polymers when heated are softened
(thick fluid like) and hardened when they can cool down, forming a hard mass. They do not
contain any cross bond and can easily be shaped by heating and using moulds. A common
example is Polystyrene or PVC (which is used in making pipes).

8
iii) Thermosetting:

Thermosetting plastics are polymers which are semi-fluid in nature with low molecular
masses. When heated, they start cross-linking between polymer chairs, hence becoming hard
and infusible. They form a three-dimensional structure on the application of heat. This
reaction is irreversible in nature. The most common example of a thermosetting polymer is
that of Bakelite, which is used in making electrical insulation.

iv) Fibers:

In the classification of polymers, these are a class of polymers which are a thread like in
nature and can easily be woven. They have strong inter-molecules forces between the chains
giving them less elasticity and high tensile strength. The intermolecular forces may be
hydrogen bonds or dipole-dipole interaction. Fibers have sharp and high melting points. A
common example is that of Nylon-66, which is used in carpets and apparels.

The above was the general ways to classify polymers. Another category of polymers is that of
Biopolymers. Biopolymers are polymers which are obtained from living organisms. They are
biodegradable and have a very well-defined structure. Various biomolecules like
carbohydrates and proteins are a part of the category. [3]

9
2.2 Types of Plastics
The main category of plastics includes;

A. Thermoplastics: PET, HDPE, LDPE, PP, PVC, PS, etc.

B. Thermoset & others: Multilayer & Laminated Plastics, PUF, Bakelite, Polycarbonate,
Melamine, Nylon etc.

2.2.1 Thermoplastics

Thermoplastics have a simple molecular structure comprising chemically independent

macromolecules. Upon heating, they are softened or melted, then shaped, formed, welded,
and solidified when cooled. Multiple cycles of heating and cooling can be repeated, allowing
reprocessing and recycling

Following comes under the categories of thermoplastics:

1. Polyethylene terephthalate (PET)

2. High-density polyethylene (HDPE)
3. Polyvinyl chloride (PVC)
4. Low-density polyethylene (LDPE)
5. Polypropylene (PP)
6. Polystyrene (PS)
7. Mixed plastics

10
 1. Polyethylene terephthalate (PET)

PET has been mainly used for various food products, mainly beverages such as mineral
water, soft drink bottle and fruit juice containers. It is suitable for large-capacity, lightweight
and pressure-resistant containers. Applications of PET include electrical insulation, printing
sheets, magnetic tapes, X-ray and other photographic film. The extensive applications of PET
would cause an accumulation of PET waste in the landfill.

Fig.2.2 Polyethylene terephthalate [13]

Properties

• Solvent resistant
• Good gas and moisture resistant
• High heat resistance
• High transparency
• Exceptionally shiny surface
• Very good stability
• Light weight
• High pressure resistance

11
2. High-density polyethylene (HDPE)
HDPE is a long linear chain polymer with high degree of crystallinity and low branching
which leads to high strength properties. The various applications contribute about 17.6% in
plastic waste category which is the third largest plastic type found in municipal solid waste
(MSW). HDPE wastes have a great potential to be used in pyrolysis process as it can produce
high liquid yield.

Fig. 2.3 HDPE Pipes for Water Supply [14]

Properties

• Excellent moisture barrier properties

• Excellent chemical resistance
• Permeable to gas
• High stiffness
• High strength
• Ease of processing
• Ease of forming

12
3. Polyvinyl chloride (PVC)

Unlike other thermoplastics such as polyethylene (PE), polystyrene (PS) and polypropylene
(PP) which can be softened by heating and solely derived from oil, PVC is exceptional since
it is manufactured from the mixture of 57% chlorine and 43% carbon.

Applications of PVC include wire and cable insulation, window frames, boots, food foil,
medical devices, blood bags, automotive interiors, packaging, credit cards, synthetic leather,
etc.

Fig. 2.4 Plastic packing film [15]

Properties

• Stable electrical insulation Properties

• Long term stability
• Good weathering ability
• Low gas permeability
• Good strength
• High density
• Good tensile strength
• Melting point range 100-260oC

13
4. Low-density polyethylene (LDPE)

In comparison to HDPE, LDPE has more branching that results in weaker intermolecular
force, thus lower tensile strength and hardness. LDPE has better ductility than HDPE since
the side branching causes the structure to be less crystalline and easy to be molded.
Commonly used as plastic bags, wrapping foils for packaging, trash bags and much more.

Fig.2.5. LDPE shopping bag[16]

Properties

• Tough material
• Waxy surface and soft scratches easily.
• Good moisture barrier properties
• Low melting point
• Good ductility
• Low tensile strength
• Flexible material
• Density range .917-.930 g/cm3

14
5. Polypropylene (PP)

PP is a saturated polymer having linear hydrocarbon chain. It has a good chemical and heat
resistance. Unlike HDPE, PP does not melt at temperature below 160 0C. It has a lower
density than HDPE but has higher hardness and rigidity which makes it preferable in plastic
industry. PP contributes about 24.3% in plastic wastes category which are the largest amount
of plastics found in MSW.

The applications include flowerpot, office folders, car bumpers, pails, carpets, furniture,
storage boxes and more.

Fig.2.6. Polypropylene plastic measuring jug [17]

Properties

• Strong, Translucent, Waxy surface

• Excellent chemical resistance
• High melting point
• Lower density
• High rigidity
• High strength

15
6. Polystyrene (PS)

PS is made of styrene monomers obtained from the liquid petrochemical. It has a structure
consists of a long hydrocarbon chain with phenyl group attached to every other carbon atom.
PS is naturally colourless, but it can be coloured by colourants.

Due to its reasonable durability, strength and lightness it is used in variety of sectors such as
in food packaging, electronics, construction, medical, appliances and toys. Unfortunately, PS
is not included in the roadside recycling program in which the recycling bins only included
glasses, papers, cans, and certain plastics.

Fig.2.7 Polystyrene foam sheet [22]

Properties

• Affected by fats and solvents

• Hard, brittle, Rigid
• Glassy surface
• Amorphous in nature
• Relatively in expensive.
• High impact resistance
• High heat resistance
• Flame retardant

16
7. Mixed plastics

Mixed plastics is a term that covers all non-bottle plastic packaging sourced from the
domestic waste stream and includes rigid and flexible plastic items of various polymer types
and colors that are typically found in the household bin. It excludes plastic bottles and non-
packaging items

The remaining plastics include: polycarbonate, polylactide, acrylic, acrylonitrile butadiene,

styrene, fiberglass, and nylon. Of course, there are many differences in the plastics classified
as miscellaneous by recycling programs.

17
2.2.2 Thermoset plastics
Thermoset plastics polymers cross-link together when curing to form an irreversible chemical
bond. It is one of two organic polymer-based plastic materials, the other being thermoplastic.

Thermoset plastics permanently form a rigid three-dimensional structural network that

immobilizes the molecules.

1. 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, thermally insulation foams. It
is a type of thermosetting plastic.

Fig.2.8 Phenol formaldehyde resin [18]

Properties

• Improved strength
• Dimensional stability
• Improved impact resistance

18
2. 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.

Fig.2.9 Urea-formaldehyde adhesives [19]

Properties

• Heat distortion temperature property

• Low water absorption property
• High surface hardness
• High tensile strength
• Mould shrinkage ability

19
3. 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).

Fig. 2.10 Melamine formaldehyde plates [20]

Properties

• Very hard
• Very durable
• Good fire and heat resistant
• Clear and colour less
• Better moisture resistance
• Expensive

20
4. Epoxy resin (Epoxide, ER)

Good electrical insulator, hard, brittle unless reinforced, resists chemicals well.
Used for casting and encapsulation, adhesives, bonding of other materials. Used for printed
circuit boards (PCB’s) and surface coatings.

Fig.2.11. epoxy resin adhesives [22]

Properties

• Superb mechanical strength

• Cheaper and faster then welding
• Suitable for broad range applications
• Excellent chemical resistance

21
2.3 Advantages of Plastics:
• They are light in weight.
• They are strong, good and cheap to produce.
• They are unbreakable.
• Used to make - Water bottles, pens, plastic bags, cups etc.
• They are good water resistant and have good adhesive properties.
• They can be easily moulded and have excellent finishing.
• They are corrosion resistant.
• They are chemical resistant.
• Plastic is used for building, construction, electronics, packaging and transportation
industries.
• They are odorless.

2.4 Disadvantages of Plastics:

• They are non-renewable resources.
• They produce toxic fumes when burnt.
• They are low heat resistant and poor ductile.
• They are non-biodegradable.
• They harm the environment by choking the drains.
• The poisonous gaseous product produced by the decomposition plastic can causes
CANCER.
• They get embrittled at low temperature and deformed at high pressure.
• The recycling of plastic is a cost ineffective process and even more expensive
compared to its manufacturing.

22
2.5 Consumption of Plastics and Generation of Plastic wastes

In India alone, the demand for the plastics is about 8 million tones per year. More than 10,000
metric tones per day plastics are produced in India and almost the same amount is imported
from other countries. The per captia consumption of plastics in India is about 3kg when
compared to 30kg to 40kg in the developed countries.

The global production of plastic has reached about 350 million tons in 2015 . The continuous
rising of plastic demand led to the growing in waste accumulation every year. It was reported
that 33 million tons of plastic waste are generated in the US based on 2013 statistic. As in
Europe, 25 million tons of plastic ended up in waste stream during the year of 2012. [4]

Fig 2.12 Global Plastic Production [24]

23
2.5.1 Growth of Waste in India
India generates 25,940 tonnes of plastic waste every day, but 40% of it remains uncollected
causing choking of drainage and river systems, littering of the marine ecosystem, soil and
water pollution, ingestion by stray animals, and open air burning leading to adverse impact on
human health and environment.

It noted that nearly one-sixth of the total plastic waste is generated by 60 major cities, with
Delhi, Chennai, Kolkata, Mumbai and Bengaluru together generating more than 50% of the
total ‘contribution’ from these cities. The Central Pollution Control Board (CPCB) had
conducted a study in these 60 major cities of India. It reported that these cities everyday
generate in total 4,059 tonnes of plastic waste. Extrapolating this plastic waste generation
data from the cities during 2010-12, the board had last year estimated the country-wide data
on plastic waste and submitted it to the ministry. It found that that 10,376 tonnes (40%) out of
25,940 tonnes of plastic waste per day remain uncollected. [2]

Fig. 2.13 Waste generation in India [2]

24
 State wise Waste Plastic Production in India( tons per annum)

State 2011 2016-2017 2017-2018

Andhra Pradesh 28,888 82863 -
Arunanchal - - -
Assam 31000 24030 -
Andaman & - 365 -
Nicobar
Bihar - 2280 2280
Chhattisgarh - 7300 -
Chandigarh 5548 21516.75 12775
Daman & Diu - - -
Delhi - 232732 -
Goa 415 - -
Gujarat - 271092 269808
Himachal - 255 -
Haryana - 23369.09 -
J&K - - 27870
Jharkhand 16691.05 - -
Karnataka - 419600 -
Madhya Pradesh 16196.51 50457.07 61037
Maharashtra 1045.24 21420.33 -
Manipur 10 - 24
Meghalaya - 13.265 15.096
Mizoram - - -
Nagaland - - 14052.5
Odisha - 6890.805 12092.20
Punjab 31000 163423.4 54066.1
Rajasthan - - -
Sikkim - 102.7 -
Tamilnadu - 79114.792 -
Telangana - - -
Tripura 182.50 30 28.5
Uttar Pradesh - 152492.64 206733.45
Uttarakhand - - -
West Bengal 200750 - -
Puduchery - 9252.25 -
Kerala 109500 - -

25
CHAPTER 3
PLASTIC WASTES
Plastic wastes can be classified as industrial and municipal plastic wastes according to their
origins. These groups have different qualities and properties and are subjected to different
management strategies. Most of the Plastic wastes come from municipal wastes, some
amount of plastic wastes generated as by-product in oil industry and agriculture. Of total
plastic waste, 78 weight% of plastic waste is thermoplastics and the remaining is thermosets.
Thermoplastics are composed of polyolefins such as polyethylene, polypropylene,
polystyrene and polyvinyl chloride and can be recycled. Thermosets mainly include epoxy
resins and polyurethanes and cannot be recycled.

Sources of Plastic Wastes

1. Municipal plastic wastes (MSW)
2. Industrial plastic wastes

3.1 Municipal plastic wastes (MSW)

The various sources of MSW plastics includes domestic items (food containers, packaging
foam, disposable cups, plates, cutlery, CD and cassette boxes, fridge liners, vending cups,
electronic equipment cases, drainage pipes, carbonated drinks bottles, plumbing pipes and
guttering, flooring. cushioning foams, thermal insulation foams, surface coatings, etc.),
agricultural (feed bags, fertilizer bags, and in temporary tarpaulin-like uses such as covers for
hay, silage, etc.), wire and cable, automobile wrecking, etc.

Thus, the MSW collected plastic wastes contains major components of polyethylene,
polypropylene, polystyrene, polyvinyl chloride, polyethylene terephthalate, etc. The
percentage of plastics in MSW has increased significantly in previous decades. Consequently,
recycling of municipal plastic wastes should deal with plastic mixtures of polyethylene,
polypropylene and polystyrene, provided that the above separation procedures are practiced.
[5]

26
Waste separation at the household would be a better option with where household wastes are
separately disposed into three parts:

• combustibles such as paper, kitchen waste, textiles, and wood,

• incombustibles such as metals, glass, ceramics, and
• plastics.

Fig. 3.1 Sources of municipal plastic waste [2]

27
3.2 Industrial plastic wastes

Industrial plastic wastes so-called Primary Waste are those arising from the large plastics
manufacturing, processing and packaging industry. The industrial waste plastics mainly
constitute plastics from construction and demolition companies (e.g. polyvinyl chloride pipes
and fittings, tiles and sheets) electrical and electronics industries (e.g. switch boxes, cable
sheaths, cassette boxes, TV screens, etc.) and the automotive industries (spare-parts for cars,
such as fan blades, seat coverings, battery containers and front grills). Most of the industrial
plastic waste have relatively good physical characteristics i.e. they are sufficiently clean and
free of contamination and are available in fairly large quantities. It has been exposed to high
temperatures during the manufacturing process which may have decreased its characteristics,
but it has not been used in any product applications. Municipal plastic wastes are
heterogeneous and Industrial plastics wastes are homogeneous in nature. For homogeneous
plastic wastes, repalletization and remolding seem to be a simple and effective means of
recycling. But when plastic wastes are heterogeneous or consist of mixed resins, they are
unsuitable for reclamation. [5]

Packaging Others Agriculture

Automobile Electronic Equipment Construction and demolition

Fig. 3.2 Sources of Industrial Waste from various industries[2]

28
3.3 Problems arising in disposal of Plastic Wastes
Different issues arise in disposal of waste plastics as given below:

• Release of fugitive emissions during polymerization process.

• Release of harmful gases such as Carbon Monoxide, Formaldehyde etc. during product
manufacturing.
• Land become infertile due to indiscriminate plastic waste disposal.
• Release of toxic emissions such as Carbon Monoxide, Chlorine, Hydrochloric Acid, Dioxin,
Furans, Amines, Nitrides, Styrene, Benzene, 1, 3- butadiene, CCl4, and Acetaldehyde on
burning of plastics waste including polyvinyl chloride (PVC).

• Leaching of toxic metals into underground water such as Lead and Cadmium pigments
due to indiscriminate dumping of plastic waste on land.
• Multilayer, metalized pouches and other thermoset plastic pose disposal problems.
• Sub-standard plastic carry bags, thin packaging films etc. pose problem in collection and
recycling and reuse.
• Indiscriminate and littered plastic waste pose unaesthetic look and choke the drain.
• Soiled and mixed plastics waste interferes its beneficial utilization.
• Unsound of plastic waste and running of recycling industries in non-conforming areas
releases fugitive emissions. [2]

29
CHAPTER 4

Concept of 4Rs- (Reduction, Reuse, Recycling and Recovery)

Reduction, reuse and recycling are known in the industry as the 3Rs. Companies sometimes
focus only on the first three in resolving waste management problems. 4Rs solutions is more
innovative way to manage waste using technology and more awareness. [6]

4.1 Reduction
Minimizing the consumption of raw material true improvement in the design the products
may allow a significant reduction in the design of products and in the amount of waste
generated when they reached through end of the life cycle.

Decreasing in the weight food container cab be seen in the last 20 years but there is a limit to
the which can be made by weight reduction in the mechanical properties and performance of
the products are also affected by the decrease.

4.2 Reuse
This is mainly applied to packaging goods been defined as any operation by which the
packaging items are refilled or used for the same purpose for which they were made with or
without the support of auxiliary products.

Consumer and industries encourage to promote the reuse of Goods and packaging instead of
disposal. This option can be applied for containers such as bottles, bags, etc.

4.3 Recycle
This allows the waste to be reintroduced into the consumption cycle Generally and secondary
applications because in many cases the recycle products of lower quality then the virgin ones.
The recycling must be applied only when the amount of energy consumed in the recycling
process is lower than the energy required for the production of new materials. plastics can be
recycled by using two different approaches Mechanical Recycling, Feedstock recycling.

30
In the first case plastics are recycled as polymers whereas in the second case Plastic waste are
transformed into Chemical or fuels.

4.4 Recovery
When the recycling of waste is not feasible or there is no market for the recycle product
incernation can be used to generate energy from the waste combustion heat.
Plastics materials of high calorific value in the Plastic waste greatly contribute to the energy
produce in the incarnation plant.
Alternatively, they can be used as fuel in number of applications like powerplants, Industrial
furnaces and cement industries.

Fig. 4.1 Showing symbol of 4R [6]

31
4.5 Recycle code of Recyclable Plastics

Fig 4.2. Recycle code of plastics

32
CHAPTER 5

VARIOUS PLASTIC WASTE MANAGEMENT TECHNIQUE

Due to population increase, the demand for plastic products has constantly increased over the
last 30 years. Since plastics are non-biodegradable, they cannot be easily returned to the
natural carbon cycle, hence the life cycle of plastic materials ends at waste disposal facilities.
The suitable treatment of plastic wastes is one of the important needs of the waste
management and is important from energetic, environmental, economical and political
aspects. In most developed societies, domestic organic waste including plastics packaging, is
disposed by land filling or by incineration. During early 2000, the largest amount of plastic
waste is disposed by land filling (65–70%) and incineration (20–25%). Recycling is only
about 10%. This varies from country to country, however they are approximately nearer to it
with some exception.

33
5.1 Landfilling

Highest portion of the solid waste including plastics have been subjected to landfill.
However, disposing of the waste to landfill is becoming undesirable due to legislative
pressures (where waste to landfill must be reduced by 35% over the period from 1995 to
2020), rising costs, the generation of explosive greenhouse gases (such as methane) and the
poor biodegradability of commonly used packaging polymers. In light of these hazards, the
Environmental Protection Agency (EPA) has improved federal regulations for land filling by
normalizing the use of liners in the landfill bed, ground water testing for waste leaks, and post
landfill closure care. However, since waste plastics have a high volume to weight ratio,
appropriate landfill space is becoming both scare and expensive. So, the other methods
outlined in should be preferred as an alternative waste management procedure to replace land
filling. [5]

Analysis of raw Landfill Gas

Component Chemical Formula Content
Methane CH4 40–60 (% by vol.)
Carbon dioxide CO2 20–40 (% by vol.)
Nitrogen N2 2–20 (% by vol.)
Oxygen O2 <1 (% by vol.)
Heavier hydrocarbons CnH2n+2 <1 (% by vol.)
Hydrogen sulfide H2S 40–100 ppm
Complex organics – 1000–2000 ppm

34
Advantages of Land Filling
• Volume can increase with little help of people/equipment.
• Other community purposes can also be done on that filled land.

Disadvantages of Land Filling

• Completed land filled areas may require maintenance.
• Require proper planning, design and operation.
• Responsible for pollution.

Fig. 5.1 Landfilling [12]

35
5.2 Mechanical Recycling

Mechanical recycling is reprocessing of the used plastics to form new similar products. This
is a type of primary and secondary recycling of plastic where the homogeneous waste plastics
are converted into products with nearly same or less performance level than the original
product suitable for second use. Practical experience has shown that reprocessing of mixed
contaminated plastics produces polymer polyblends that are inferior mechanically and
lacking in durability (due to peroxidation) compared with those produced from virgin
polymers.
Material recycling of household waste plastics is particularly difficult when they are
contaminated with biological residues or, as is usually the case, when they are a mixture of
different kinds of plastics. Technology is being introduced to sort plastics automatically,
using various techniques such as X-ray fluorescence, infrared and near infrared spectroscopy,
electrostatics and flotation.
However the economic viability and practicability of such process in industrial application is
not apparent. Entrepreneurial effort has gone into the development of special processing
equipment to convert mixed plastics wastes to wood or concrete substitutes in the
manufacture of fence posts, benches, boat docks, etc., but there are serious doubts about the
ecological benefits of doing this. Some limited success has been achieved with mixed plastics
wastes in the manufacturing of plastics-based underground chambers by increasing wall
dimensions to match the load-bearing strength of concrete.
In this application, there is no significant long-term deterioration due to exposure to the
weather, but this procedure could never utilize more than a small fraction of the mixed
polymer wastes available. This is an expensive and energy-intensive procedure which cannot
be justified for domestic mixed plastics wastes. In this way, it is apparent that mechanical
recycling, although employed widely, is not a suitable method when the quality of secondary
produce and ecological aspects are considered. [7]

36
It consists of various processes:
• Milling
• Agglutination
• Extrusion
• Addition of additives
• Quenching
• Granulation

Advantages
• Recycling of waste plastic into useful secondary product has been achieved.
• Does not responsible for green-house gas emission.

Disadvantages

• Reprocessed product of mixed contaminated plastics are inferior mechanically and

lacking in durability.

• Expensive and energy intensive process.

• The economic viability and practicability of such process in industrial application is

not apparent.

Fig. 5.2 Flowsheet of Mechanical Recycling [12]

37
5.3 Biological Recycling

Both natural and synthetic cis-poly (isoprene) become highly resistant to bio-degradation
when made into industrial products (e.g. tyres) which is a direct consequence of the presence
of highly effective antioxidants added during their manufacture. This has led to intensive
research to develop polymeric materials that conform to user requirements but are also
returned to the biological cycle after use. This resulted in development of biodegradable
polymers which can be converted back to the biomass in a realistic time period.

Biodegradable plastics are already being used successfully in different countries. Mostly they
are introduced in food/catering industry which photo-degrades in six weeks. There is also
potential to use such plastics in non-packaging applications such as computer or car
components. However, there are a number of concerns over the use of degradable plastics.
First, these plastics will only degrade if disposed in appropriate conditions. For example, a
photodegradable plastic product will not degrade if it is buried in a landfill site where there is
no light. Second, they may cause an increase in emissions of the greenhouse gas methane, as
methane is released when materials biodegrade anaerobically.

The mixture of degradable and non-degradable plastics may complicate plastics sorting
systems. Finally, the use of these materials may lead to an increase in plastics waste and litter
if people believe that discarded plastics will simply disappear. Due to all these problems at
present the biodegraded plastics cannot substitute all the application areas of synthetic
plastics. [5]

Advantages
• Biodegradable polymers can be converted back to the biomass in a realistic period.
• Mostly they are introduced in food/catering industry which photo-degrades in six
weeks.

38
Disadvantages
• Appropriate conditions are required for degradation of these plastics. Ex-
photodegradable plastic product will degrade only in presence of light.
• Responsible for green-house gas emission.

Fig. 5.3 Cycle of Biological Recycling [23]

39
CHAPTER 6
THERMO CHEMICAL RECYCLING

Plastics are manufactured from crude oil or natural gas. Thermo Chemical recycling of plastic
waste involves heating plastic which the waste plastic molecules chemically decompose into
crude oil. This crude while is further heated to temperatures of 450°C to convert it into
mixture of petrol, diesel and kerosene. Hydrocarbon gas and carbon black powder produced
as a byproduct of this process

It is an advancement of existing energy from waste (EFW) technology. An ATR system

converts municipal solid waste (MSW) into either electricity or steam for district heating or
industrial customers. It is also known for its waste to energy conversion processes.

The combustion bottom ash and the combustion fly ash, along with the air pollution control
system fly ash, are treated to produce products that can be beneficially reused. Specifically,
ATR systems consist of the following:

• Solid waste combustion, boiler and combustion control system, energy recovery and air
pollution control equipment;
• Combustion bottom ash and fly ash treatment systems that produce commercially
reusable products; and
• An optional pre-processing system to recover recyclable materials contained in the MSW
delivered to the facility before the MSW enters the thermal processing area of the facility.

It can be classified into mainly three type

1. Incineration
2. Gasification
3. Pyrolysis

40
6.1 Incineration
Burning or incineration are the least desirable and the most environmentally harmful methods
of plastic waste disposal. Open burning of plastic waste generates harmful air-pollution
which includes high quantities of suspended particulate matter, dioxin, furans and volatile
organic matters.

In incineration method plastic waste disposal, the plastic waste is burned, and the heat is used
for production of steam. The steam produced is used for producing electricity. During the
compression of plastic waste, the harmful chemicals like dioxins and furans are produced.

The most effective way to reduce the volume of solid waste is to burn it in a properly
designed and operating condition, the process called as incineration. In an ideal incineration
process, the hydrocarbon compounds of the combustible residue combine chemically with the
molecular oxygen to generates carbon dioxide and water, and as a residue generates oxides of
metals and minerals. [5]

The basic advantages of incineration are

• they require less land and be effectively used for energy generation.
• including volume reduction,
• immediate disposal without waiting favorable attributes,
• immediate disposal without waiting for slow biodegradation process,
• less land requirement,
• destruction of hazardous materials,
• value addition to waste product by energy recovery or by generating electricity.

The major step involved in incineration are

• Storage of waste
• Preparation of feed
• Combustion of feed
• Heat recovery
• Ash handling
• Air pollution control

41
 Fig. 6.1 Flowsheet explaining Incineration processes [7]

Most developed countries public distrust of incineration at present limits the potential of
waste-to-energy technologies as it produces greenhouse gases and some highly toxic
pollutants such as polychlorinated dibenzo para dioxins (PCDD) and polychlorinated dibenzo
furans (PCDF). The potential relationship between plastics fed into an incinerator and the
formation of dioxins and furans is still unclear and has been suggested that the chlorine
content in PVC and other plastics is related to the formation of dioxins and furans

42
6.2 Gasification

Gasification of waste is considered attractive because it can convert much of the energy
contained in the waste material into a gaseous fuel that has a range of uses. According to one
estimate, 80% of the chemical energy within the waste is extracted as a fuel making it
potentially much more efficient than incineration. The gas which is produced can be used to
manufacture chemicals, but in a waste-to-energy process, it will normally be burnt in a power
plant to generate electricity.

Gasification is a process known as partial oxidation and it has been widely used in industry
to manufacture hydrogen from fossil fuels. It can be carried out in either air or oxygen, with a
partial combustion of the waste material providing the energy needed to drive the process.
When combustion takes place in excess air—as in an incineration plant—the combustion
process, the chemical oxidation of the waste, goes to completion, and all the hydrogen and
carbon present in the waste are converted into water vapor and carbon dioxide. During partial
oxidation, the amount of oxygen is restricted. Under these conditions, the combustion
reactions cannot go to completion and the main products are carbon monoxide and
hydrogen.[8]

Gasification is the thermal conversion of any carbon-based material with a small amount
of air or oxygen in a heated chamber, into a mixture of combustible gases (hydrogen,
carbon monoxide, carbon dioxide and some trace compounds) called syngas. The syngas
may have a heating value of 200 to 500 Btu per cubic foot and can be either used as a fuel
for energy production or further processed to a wide variety of fuels and chemicals.

In the gasifier, the feedstock is converted through several sequential processes. First, the
feedstock is homogenized into smaller particles then inserted into the gasifier, followed
by a controlled amount of air or oxygen (and steam for some gasifiers). Feedstock passes
through several temperature zones where a sequence of reactions occurs before the syngas
produced is removed from the chamber. The temperatures in a gasifier typically range
from 1,100 to 1,800 degrees Fahrenheit. Solid residue is removed from the bottom of the
reaction chamber. [8]

43
System Feedstock (Inputs)
Most commonly used feedstocks include:
Waste Wood
Wood Pellets and Chips
Aluminum Wastes
Plastics
Industrial Wastes
Municipal Solid Waste (MSW)

Fig. 6.2 Flowsheet explaining gasification [12]

44
 Outputs
The main output of gasification is the syngas that may be used for various useful
products. Some products can be used immediately without further processing, while
others require simple or complex conditioning and/or processing before use in specialty
applications.
The syngas can directly be combusted for recovery of the thermal energy as heat and/or
steam and electricity. The heat is used to provide property- or district-heating or cooling
an GBB 20 August 13, 2013 application often used at biomass, wood waste, and
industrial waste gasifiers throughout the world.

The syngas can be converted to liquid fuel products. This liquid product can be further
refined to different types of fuels, from crude. sand diesel to kerosene. Syngas can be
processed to chemicals such as methanol and hydrogen. Methanol can be further
transformed to different fuels or chemicals including ethanol, acetic acid, formaldehyde,
methyl acetate, commonly used in industrial and commercial processes.

Advantages

• Opportunity to utilize wood and agricultural waste for energy generation and cut
disposal cost
• Cogeneration of heat and/or provision of cooling along with electricity
• Allows better process control and convenience
• Elimination of all pollution related to Biomass use
• Cleaner combustion in connected equipment

Disadvantages
• Hard to compete with cheaper sources such as coal, oil and nuclear
• Small amount of tar is released in the gas.
• Emission of toxic and harmful gases during process
• Syn gas is not up to not standard for directly used for energy conversion.

45
6.3 Pyrolysis

Pyrolysis of plastic waste currently gained high attention from the researchers for converting it to
liquid fuel to overcome the depletion of liquid fossil fuels. Pyrolysis is generally defined as the
controlled burning or heating of a material in the absence of oxygen. The word is coined from the
Greek-derived elements pyro "fire" and lysis "separating".

It is a tertiary recycling technique in which organic polymers are converted into liquid oil, char and
gases at high temperatures by thermal decomposition. Pyrolysis differs from other high-temperature
processes like combustion and hydrolysis in that it usually does not involve reactions with oxygen,
water, or any other reagents.

In plastics pyrolysis, the macromolecular structures of polymers are broken down into smaller
molecules or oligomers and sometimes in monomeric units. Further degradation of these subsequent
molecules depends on several different conditions including temperature, residence time, presence of
catalysts and other process conditions. [9]

In some context, the term “cracking” is used instead of pyrolysis. Now a days, it is a common
practice to differentiate thermal pyrolysis from catalytic pyrolysis. The former refers to the
decomposition of polymers due to the application of heat alone, while the latter refers to the processes
where catalyst is utilized to alter the reaction mechanism of pyrolysis, hence the products yield and
composition. The pyrolysis reaction can be carried out with or without the presence of catalyst. Since
majority of plastic used are polyolefins, hence extensive research has been done on this polymer.

The product formed from the pyrolysis process are oil, syn gas, char. Volatile matter and ash content
are the major factors that influence the liquid oil yield in pyrolysis process. High volatile matter
favored the liquid oil production while high ash content decreased the amount of liquid oil,
consequently increased the gaseous yield and char formation. plastics have high potential to produce
large amount of liquid oil through pyrolysis process. It should be noted that the product yield and
quality heavily depend on the set-up parameters. Therefore, this review focused on different type of
plastic pyrolysis that has been explored together with the main affecting parameters in plastic
pyrolysis process that need an attention to maximize liquid oil production and enhance the oil quality.
The main parameters include temperature, type of reactors, residence time, pressure, different
catalysts usage and type of fluidizing gas with its flow rate. [9]

46
 Fig. 6.3 Block diagram of Pyrolysis waste to valuable products. [16]

Studies have been started from analyzing the characteristics of liquid fuel produced from different
type of plastics in order to upgrade the liquid quality. In terms of quantity, most researchers reported
high amount of liquid yield more than 80 wt% that could be produced in pyrolysis of individual
plastic, which was higher than the pyrolysis of wood-based biomass in general. As for the quality, the
obtained liquid also had high calorific value. With the addition of catalyst, the impurities contained in
plastic waste could be removed reducing the water content in liquid fuel.

47
5.3.1 Thermal pyrolysis
The non-catalytic/thermal pyrolysis of polyolefins is a high energy, endothermic process which
requires temperatures of at least 350–500 0C. Thermal pyrolysis of waste plastics as well as other
hydrocarbon resources has been studied extensively in the past. A number of these thermal cracking
studies are on polyethylene, polystyrene and polypropylene while only a few have worked on the
thermal decomposition of other common plastics such as polyvinylchloride, polymethyl methacrylate,
polyurethane and polyethylene terephthalate.

Generally, thermal cracking gives liquids of low octane value and higher residue contents at moderate
temperatures. It is an inefficient process for producing gasoline range fuels. The gaseous products
obtained by thermal pyrolysis are not suitable for application as fuel products and require further
refining to be upgraded to useable fuel products .[10]

Fig. 6.4 Thermal Pyrolysis setup [10]

48
6.3.2 Catalytic Pyrolysis
The catalytic pyrolysis is carried out in the presence of catalyst. The catalytic processes have high
potential for the conversion of plastic waste into liquid oil It gives better product quality at lower
temperatures and reaction times when compared to thermal pyrolysis. These factors reduce the
process energy demand and thus optimize the overall pyrolysis process. Presence of catalyst enhances
the conversion and fuel quality. The effect of catalyzed decomposition of polymers has spurred a
wave of research in the area of catalysis and polymer degradation. And hence, Catalytic degradation
of plastics is found to have greatest potential to be developed into a commercialized process. [11]

Fig. 6.5 Catalytic Pyrolysis Flowsheet [11]

49
6.3.3 Design parameters of a Pyrolysis unit

Desirable parameters for the design

a) Melting point of the substance

If melting point is high, substance easily vaporizes & more oil is obtained.

b) Density

If density is lower, substance easily vaporizes & more oil is obtained.

c) Quality of substance

More is quality, more is the yield of oil.

d) Moisture content

More is moisture, less is the oil yield.

e) Reactor Temperature

More is the reactor temperature, more is the yield.

f) Heating rate

More is the heating rate, more is the yield.

g) Reactor size

Optimum reactor size to get maximum oil yield.

h) Feed rate

Feed rate is given according to the demand for the oil.

f) Maintaining a uniform temperature

For continuous production it should maintain a uniform temperature.

g) Types of condenser used

Condenser design also effects the production of maximum product yield.

50
Steps involved in process

1. Feeding- Feed the feedstock to reactor through feeder and closes the feeder inlet.

2. Heating- To increase the temperature of reactor, heat the product of reactor inside by using
heating source.

3. Condensing- The plastic gets evaporated at high temperature, this vapor is condensed to
atmospheric temperature by using straight and spiral tube condensers.

4. Liquid collection- Out coming product from the condenser is collected at liquid collector.
At the end of condenser provide a cyclone separator to separate the plastic liquid fuel and
non-condensable gases. These non-condensable gases are reuses to heat the pyrolysis unit.

5. Water wash, Purification and pH test- This involves many purification processes. In this
method we take equal proportion of plastic fuel and water in a container and shake well,
allow it for 5-7 hours to settle down. Now water along with some crystals is collected at
bottom and pure plastic fuel is collected at the top container.

6. Purification- Purify the plastic fuel by using filter papers and filters.

7. pH Test- After purification measure the pH value of plastic fuel by using pH meter. If the
pH is less than 7, the fuel is acidic in nature. It is needed to wash with water many times to
bring pH value of oil to 7.

Advantages
• Pyrolysis can be performed at relatively small scale and at remote locations which
enhance energy density of the biomass resource and reduce transport and handling
costs.
• Biomass pyrolysis offers a flexible and attractive way of converting organic matter into
energy products which can be successfully used to produce heat, power and chemicals.
• A wide range of biomass feedstocks can be used in pyrolysis processes

Disadvantages

• However, pyrolysis is less polluting than incineration, it too has some serious negative
environmental aspects.
• Efficiency is not as much as in other modern plastic to energy conversion techniques.

51
6.4 Comparing Incineration, gasification and pyrolysis

Factor Incineration Gasification Pyrolysis

Input Plastic waste Plastic waste Plastic waste
Product Flue gas, ash and Syn gas Oil, gas, Char
heat
Method Heating in presence of Heating in limited Heating in absence of
oxygen supply of oxygen oxygen

Catalyst use during No catalyst used silica alumina, zeolites

process (beta, USY, ZSM-5,
REY, clinoptilolite,
etc.), and MCM-41.
% of air content Almost 100% 20-40% No required
during process
Process Temperature 200-400 OC 600-800 0C 300-800 oC
range
Combustion Complete Partial none
Calorific Value of None Low calorific value High calorific value
Product
Emission Generate emissions By using less oxygen, Causes Less pollution
that causes pollution. fewer air emissions as compared to
are produced. incineration and
gasification.
Uses heat generated by The syngas may be gases, oils and solid
incineration can be used to generate char produced can be
used to generate energy more used as a fuel, or
electric power. efficiently, if a gas purified and used as a
engine (and feedstock for Petro-
potentially a fuel cell) chemicals and other
is used applications.

52
CHAPTER 7

CONCLUSION
Increasing demand of plastics day by day producing the higher amount of waste. This project
analysis has observed the use of waste plastics, a factory planning and its feasibility in
Metropolitan City. It is easily assumed that, when the use of waste plastic will increase then
the solid waste management will search more ways to find out to collect them.

The implementation of this project can develop so many opportunities in the city. It can be a
solution to control waste plastic, develop a new technique or idea, and detect the source of
fuel for the country.

Both Pyrolysis and gasification technologies have been successful in processing biomass and
homogeneous industrial waste products. Their application in the field of MSW processing is
under development.

The energy obtained in incineration can be used to run the turbine to generate electricity as a
result of which waste to energy conversion is achieved.

The syn gas obtained from gasification process can be converted into many products such as-
naptha, wax, gasoline.

The use of plastic pyrolysis oil in diesel engine in the aspect of technical and economical is
compared and found that oil can replace the diesel oil.

Pyrolysis method is superior in all respects (ecological and economical). By adopting this
technology, efficiently convert weight of waste plastics into 75% of useful liquid
hydrocarbon fuels without emitting any pollutants. It would also take care of hazardous
plastic waste and reduce the import of crude oil. Depletion of non-renewable source of
energy such as fossil fuels at this stage demands the improvements of this technique.

53
CHAPTER 8

Future aspects of Plastic Waste to energy

• The target of clean INDIA (Swachh Bharat) can be achieved only through reusing and
recycling of waste plastics.
• As there is a high demand of crude oil and due to its sky reaching prices, large- or
small-scale industries can produce the fuel locally at much cheaper rates directly
benefiting the National economy.
• Recycling plastic waste can create more jobs in the country.
• It will reduce the dependency on gulf countries for fuel requirements and helps in
development of country.
• Energy crisis can be prevented by using waste plastic as an alternative source of fuel.
• Advancement of technology will increase the value of process of plastic waste .
• Requires more research and development for making it economically affordable.

54
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55
ab.3..0.3218292.3225088..3227301...1.0..4.318.1564.2-5j1......0....1j2..gws-
wiz.....6..0i71j33i21j35i39.GjGxmHxRMfg.

[13]
https://www.google.co.in/search?q=pet+plastic&rlz=1C1RLNS_enIN847IN847&source=lnm
s&tbm=isch&sa=X&ved=0ahUKEwiX0BuYviAhUFT48KHT98CUoQ_AUIDigB&cshid=1
557302025878734&biw=1536&bih=722

[14]
https://www.google.co.in/search?rlz=1C1RLNS_enIN847IN847&biw=1536&bih=722&tbm
=isch&sa=1&ei=Ro3SXOD6M7Xez7sP8ersAs&q=hdpe+plastic+pipe&oq=hdpe+plastic+pip
e&gs_l=img.3..0j0i24l6.8889.10245..10704...0.0..0.237.1039.0j2j3......1....1..gwswizimg.......
35i39j0i67.ctZN0rPwn9g#imgrc=W4wqKi7atlvoJM:

[15]
https://www.google.co.in/search?rlz=1C1RLNS_enIN847IN847&biw=1536&bih=722&tbm
=isch&sa=1&ei=8I3SXPa7ELG48QPL4bfQBg&q=pvc+plastic+film&oq=pvc+plastic+film
&gs_l=img.3..0i24l2.13225.14631..14891...0.0..1.1096.2253.41j1j0j1......1....1..gwswizimg....
...0i8i30.PudydQsnedA#imgrc=CFVuLnesakJ6lM:

[16]
https://www.google.com/search?biw=1396&bih=612&tbm=isch&sa=1&ei=KJDSXJ3UL5Oe
vQTdipbIBA&q=pp+plastic&oq=pp+plastic&gs_l=img.3..0l10.4577.7883..8480...0.0..0.172
2.6478.0j1j1j0j1j0j1j1j2......1....1..gws-wiz-
img.......0i67.bWEGUziAI8k#imgrc=R_50TFpbp0LPqM:

[17]
https://www.google.com/search?biw=1396&bih=612&tbm=isch&sa=1&ei=NJDSXMq3D8m
6vgSIi6HYDg&q=polystyrene&oq=polystyrene&gs_l=img.3...323945.328157..328387...0.0.
.0.0.0.......1....1..gws-wiz-img.....0.LLom_KFks3g

[18]
https://www.google.com/search?biw=1396&bih=612&tbm=isch&sa=1&ei=gJHSXPngIc7dz
7sP2byasAI&q=ldpe&oq=ldpe&gs_l=img.3..35i39j0j0i67j0l3j0i67j0l3.270435.273034..2733
21...0.0..4.366.1899.0j1j3j3......2....1..gws-wiz-
img.....0.ejvmO9B2UfM#imgrc=xcmW2MVtAL6XwM:

56
[19]
https://www.google.com/search?q=urea+formaldehyde&source=lnms&tbm=isch&sa=X&ved
=0ahUKEwj78sH_xoviAhVJbn0KHRFxB34Q_AUIDigB&biw=1396&bih=657#imgrc=1E7
SuYGty7RN7M:

[20]
https://www.google.com/search?biw=1396&bih=657&tbm=isch&sa=1&ei=ipjSXISOG9fTz
7sP64W6eA&q=melamine+formaldehyde&oq=melamine+formaldehyde&gs_l=img.3..0i67j
0l8j0i67.400090.413713..415609...0.0..3.250.4453.0j23j2......2....1..gws-wiz-
img.....0..35i39.d6t0sjK51AI

[21] https://www.google.com/search?biw=1396&bih=657&tbm=isch&sa=1&ei=K5rSXLX-
B_zbz7sP0pCuwAM&q=epoxy+resin&oq=epoxy+resin&gs_l=img.3..0i67j0j0i67j0l2j0i67j0
l4.345293.350427..351437...0.0..4.307.3171.0j8j6j1......2....1..gws-wiz-
img.....0..35i39.cqnwbxBh0rQ

[22]https://www.google.com/search?biw=1396&bih=612&tbm=isch&sa=1&ei=NJDSXMq3D8
m6vgSIi6HYDg&q=polystyrene&oq=polystyrene&gs_l=img.3...323945.328157..328387...0.0.
.0.0.0.......1....1..gws-wiz-img.....0.LLom_KFks3g

[23]https://www.google.com/search?biw=1396&bih=657&tbm=isch&sa=1&ei=KgDTXMSZHo
7Yz7sPjfCbmAc&q=bio+logicalrecycling&oq=bio+logicalrecycling&gs_l=img.3...3820239.383
0894..3831663...0.0..3.296.4405.0j16j7......2....1..gws-wiz-
img.....0..0i67j0j35i39j0i10i67j0i10j0i8i30j0i30j0i24j0i10i24.egHapV_EP48#imgrc=9GWlq_yP
y7ln-M:

[24]https://www.google.com/search?biw=1396&bih=657&tbm=isch&sa=1&ei=JA_TXPfSJpKf
mge4yIyoBg&q=global+production+of+plastic&oq=global+product&gs_l=img.1.0.35i39j0l9.1
23961.131812..134329...0.0..4.852.4059.0j16j0j1j6-1......2....1..gws-wiz-
img.....0..0i67j0i10.4rBjwX0i6f0#imgrc=6wscrSayybYZoM:

57