Retrieving Plastic Waste Material and Automatic Continuous Feed Pyrolysis Fuel Plant

INTRODUCTION:

This process is divided into two parts, namely the pre-screening waste plastics automatic recycle plant and the automatic continuous feeding pyrolysis renewable fuel plant.

Pre- Screening Sorting Plant

1. This plant is installed in landfills or near the MSW site and will automatically select and recover the plastic waste. The process is as follows: the plastic waste is transported daily to the automatic pre-sorting plant. After shredding the plastic bags, vibrate screening, vacuuming, magnetic selection, waste plastic extrusion are then sent to the pyrolysis plant.

The waste plastic pre-sorting recycle plant will for each 1,000 tons of fresh garbage recycle  abt. 100 tons of waste plastic material - the recovery rate is about 10%. Installing this plant can reduce mountains of landfill sites and MSW sites around the world.  This pre-sorting recycle plant can also apply to recycle waste plastic bags, waste oil, waste tires, and MSW biomass waste (agricultural waste and refuse, wood waste, wood-based residues, energy crops short-rotation crops, sweet sorghum, …etc.).

Pre-sorting process is as follows:

a.) Retrieving Plastic Waste Material, Biomass Waste from Landfills or MSW site
b.) After pre-sorting by the automatic plant, recycled plastic waste, biomass waste is sorted.
c.) The plastic waste, biomass waste is automatically packed and transported to the pyrolysis plant.

2. Waste Plastics, Biomass waste Automatic Continuous Pyrolysis Fuel Plant

This plant needs to be installed in an industrial zone and meets all the advanced countries’ environmental protection emission standards. The pre-screening waste plastic, biomass waste is converted by pyrolysis process and conversion rate is about 70 percent (cracking and refining the burning oil, unleaded petrol, diesel, gas and other valuable co-products such as carbon black, crude asphalt, coke valorization and construction aggregates ).

Regarding the biomass syngas get from pyrolysis process not only can be utilized for internal combustion engine for electric power generation, but also can be utilized for boiler or hot-blast furnace to produce steam or hot air for drying.   The gas also can be lead to tornado type dust collection tank (with stainless quality ) then send to gas burner generator system to generate the power.    Power: 0.5M-5MWatt upon quantity.

• Our company design a set of technologies based on the features of waste macromolecular materials to convert biomass and plastic wastes into renewable fuels.
• The equipment consists of 5 parts:
• Auto feeder
• Catalytic cracking & pyrolysis unit
• Heat exchange & cooling unit
• Fractional distillation unit
• Heating devices & electric control unit
• Low quality demand for the raw materials that no need to clean, dry, or classify.  Raw materials can be conveyed. A conveyor is used to feed raw materials (large pieces of waste material should be broken up in advance), the input and output will be operated at the same time.
• Oil products:
  Gasoline: Octane number 90 ~ 93
  Diesel:    premium  ~ Super(0#-1#)

Main Features:

• Removing burnt smell
  To eliminate the smell of oil products by using a special cleaning filter and detergents.
• Residue management
  Our technology can manages residue particle size over 1000 mesh can be recycled as fuel or used as filler.
• Product index:
  Diesel: sulfur≦50ppm, Hexadecane (cetane)≧2%, Distillation 95% vol point 340 ℃.
• Auto feeder
  Screw with variable pitch is used to fed raw materials continuously; automatic compression, exhausting, dehydrating, and pre-heat can be operated during Feeding process.
  Small pieces of waste materials do not need be broken up; and no need to clean raw materials.
• Residue processing unit
  Residue processing at high temperature (300℃), make continuous production possible.
• Gas Recovery system
  Safe, reliable, stable, and uncomplicated structure. 
• High Efficiency Catalyst:      
  Many catalytic reactions are involved in this sophisticated process.  The exact calculation and control on the speed rate and feed ratio prevent catalysts from damaged by toxic pollutions.  We have optimized activity, selectivity, strength, and anti-pollution of catalysts used.
• Innovation :      
  Catalytic pyrolysis occurs at low temperature (< 280℃) High yield and high conversion, with fuel more than 80%, while gas less than 5%.

Waste Plastic Pyrolysis Production line:

Feed waste plastic 10 Tons/day for example, maximum 250KW / hour electricity consumption, 9 labor ( 3 shifts for 24 hours )  Plant size is 20M x 25M = 500 MXM 
Output 8 Kilo Litre /day ( 75% Diesel, 20% gasoline , 5% gas )

Pyrolysis Major Systems:

Feeding System
Feed Stock Preheating System
Pyrolysis System
Catalytic Cracking system
Preheating Condensing System
Fuel oil Heat Exchange System
Fractionating System
Fractionating Condensing System
Fractionating Precipitation system
Air, Water Purify System
Piping System
Electrical Control System

This equipment has a very low requirement for maintenance - no cleaning or sorting, and uses an automatic conveyor feeding system, fully automated operation, high-efficiency, and capability to be operated 24 hours a day. Site safety, closed and clean production process. No second pollution. Wide range of raw materials, high conversion, average conversion rate > 70%, Diesel up to 90%.  While one side feeds the raw plastic, the other side is supplying oil and de-slagging.

All plastics are composed from crude oil - Carbon (C) and Hydrogen (H). Petroleum is composed of two components: hydrocarbons and the other non-hydrocarbons - Oxygen (O), Sulfur (S) and Nitrogen (N). The composition of petroleum hydrocarbons, the chemical polymer, namely, Carbon and Hydrogen is the major component of plastic - plastic is produced from petroleum. Waste Plastic under pressure and catalytic cracking produces fuel and can be used as a fuel source. Under certain temperature conditions the plastic macromolecular chains are converted to small molecular chains (which is a hydrocarbon compound) and those small molecular compounds contain C4 ~ C20, this compound is a component of petrol, coal oil, and diesel. Under this catalytic pyrolysis process the wax oil and heavy oil are removed.

Pyrolysis Process

The shredded plastic waste is automatically and continuously fed into the pre-heating process; the plastic waste melts at this stage, PVC as it has a low melting point will crack first and the HCL will be removed in this process.

After preheating, the melted plastic is fed into the continuous cracking furnace. The cracking furnace has a solid mesh and is cyclically heated to ensure the waste plastic is completely converted by the pyrolysis reaction. Any residues are removed automatically from the cracking furnace to ensure nontoxic operation.

The pyrolysis gas fractionation and subsequent cooling from the fractionation tower, produces light and heavy oil fractions and a small amount of non-condensable gas. The light oil fraction (light gasoline) is separated and the heavy oil fraction is fed into the re-boiler and re-processed by secondary catalytic cracking. This process produces a high-quality automotive diesel. The non-condensable gas from this purification system is used as the fuel to heat the pyrolysis system and the whole process is self-sufficient. The process by the purification system achieves all developed countries’ emissions standards.

Equipment technique:

The plant uses continuous reacting bed pyrolysis technology - the shredded recycled waste plastics is fed continuously into the cracking furnace to increase thermal efficiency and maximize processing power.

In the preheating stage, the pyrolysis plant process purifies the mixed waste plastic PVC material and harmful gases such as HCL gas are removed, this in turn protects the equipment from erosion. Inside the Pyrolysis plant the gas is fed into catalytic converter then cracked, fractionation, cooled and separated. The non-condensable gas is purified and supply for the heating process and production use, the generated flue gas purify again by the flue gas purification system to meet the developed countries’ emission standard.
The cracking pyrolysis system produces carbide and is fed onto a conveyor system to the combustion furnace for combustion and removal. The generated harmless ash is automatically collected and is environmentally cured.

Waste Plastic Pyrolysis Production line equipment:

For example - Feed waste plastic 10 Tons/day , maximum 250 kW / hour  electricity consumption, 9 labors ( 3 shifts for 24 hours )
Output 8 Kilo litre /day ( 75% Diesel, 20% Petrol , 5% fuel )

• Breaking System
• Raw material Preheating System
• Heating System
• Pyrolysis System
• Catalytic Cracking System
• Cooling System
• Gas Purify System
• Smoke Purify System
• HCL Removal System
• Dual Electrical Control and Monitoring System