Biofuels Project 2023-24

Waste plastics to oil using pyrolysis

Indian Institute of Technology (Indian School of Mines) Dhanbad

Submitted By:

Ayush Raj (21JE0214)

Parimal Kumar (21JE0631)
Pratik Patil (21JE0687)
Gautam Kumar (21JE0353)
Pratik Kumar (21JE0686)

Guided By:
Dr. B. Rajasekhar Reddy
 Contents

SR.NO. Title Page No.

1. Abstract 2

2. Introduction 3

3. Methodology 6

4. Result and Discussion 9

5. Conclusion 13

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 ABSTRACT

Plastics have become essential in modern society due to their

affordability, longevity and versatility leading to exponential growth in
production and consumption since their introduction in the 1950s.
Approximately 4% of the world's oil and gas reserves are diverted towards
plastic production and energy generation. Consequently, the increase of plastic
waste has emerged as a significant environmental challenge. However, this
plenty of plastic waste presents an opportunity for resource recovery and
sustainable energy production.

One promising technique for managing plastic waste is pyrolysis, the

process in which plastic waste is thermally decomposed in the absence of
oxygen, yielding valuable products such as pyrolysis oil and hydrocarbon-rich
gas. These products have properties comparable to fossil fuels, making them
suitable for various energy applications. Pyrolysis offers a technically and
economically feasible method for recycling plastic waste, as it eliminates the
need for extensive pre-treatment processes and allows for direct feeding of
plastic waste into the system.

Through pyrolysis, long-chain polymers in plastic waste are broken down

into smaller, complex molecules, resulting in the production of pyrolysis oil with
a high heating value of 25–45 MJ/kg. This oil can serve as a substitute for virgin
oil in power generation, transportation, and other industrial processes, thus
reducing the overall demand for fossil fuels. Additionally, the hydrocarbon-rich
gas produced during pyrolysis can be utilized for process energy recovery,
minimizing the dependence on external heating sources and enhancing the
sustainability of the process.

Overall, plastic pyrolysis presents a promising solution to the challenges

of plastic waste management and fossil fuel depletion. By converting plastic
waste into valuable resources, such as pyrolysis oil and gas, this process
contributes to the transition towards a circular economy model, where resources
are conserved, waste is minimized, and energy production is sustainable.

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 Introduction

Plastic is a material which contains an organic substance with large molecular

weight having polymers of long carbon chains. Based on its physical properties,
plastics are divided into two types:

• Thermoplastic: Plastics that are easily deformed when heated and can be
bent with ease. They have secondary bonds between their molecular
chains. Example: nylon, PVC, Polypropylene etc.
• Thermosetting: Plastics which cannot be softened again by heating once
they are molded. They have primary bonds between molecular chains and
held together by strong cross-links. Example: Bakelite, melamine, etc.

Plastic is a non-biodegradable. It can take up to 1000 years to break down, so

when it is discarded, it accumulates in the environment. Pollution due to plastic
affects marine wildlife, poisons groundwater and damages soil and it can cause
serious health issues. Plastic pollution has become one of the most crucial
environmental issues. garbage collection systems are inefficient. So, there is
always concern about plastic waste.

Why was plastic invented?

Development and production of new plastic products increased after

World War-II, In the modern era, life without plastics would be unrecognizable.
Inventors have found that plastics are a durable and lightweight material that
can be used in countless applications, from transportation to medicine. Plastics
have revolutionized the medical field, enabling life-saving devices. They have
also made space travel possible, and have lightened cars and jets, reducing fuel
consumption and pollution. Plastics have saved lives through the use of helmets,
incubators, and equipment for clean drinking water.

How plastic is threat:

Plastic pollution impacts the environment, humans, animals, birds, and

aquatic life. Environmental degradation results from plastic waste's persistence,
leaching toxins into soil and waterways. Humans suffer health risks from
consumption of microplastics, found in food and water sources. Animals and
birds face entanglement and consumption of plastic, leading to death or severe

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injury. Aquatic life ingests microplastics, contaminating food chains and causing
reproductive issues. Plastic ingestion reduces animals' nutrient intake, leading to
starvation. Overall, plastic pollution disrupts ecosystems, causes health hazards,
and threatens biodiversity.

Types of Plastic:

1. Polyethylene Terephthalate (PET or PETE): It is the plastic used to

make most water bottles. It is commonly used for food and drink
packaging and is highly recyclable.
2. High-Density Polyethylene (HDPE): It is a thicker and stronger form of
PET. It is used to make vessels for juice, milk and shampoo bottles. It can
also be recycled.
3. Polyvinyl Chloride (PVC): It is used in healthcare, automobile, building
and construction, etc. It is considered the most harmful type of plastic. It is
not recyclable.
4. Low-Density Polyethylene (LDPE): It is the most widely used plastic in
the world. It is used to make plastic bags, squeeze bottles, beverage cup
coatings, etc. However, this type of plastic is difficult to recycle.
5. Polypropylene (PP): It is a heat-resistant plastic used for hot food
containers and car parts. Unfortunately, it is not recyclable.
6. Polystyrene (PS): This is the material commonly known as Styrofoam,
which is used in food containers, cups, and packaging.

Pyrolysis:

Pyrolysis is heating substance-s at very high temperature-s in a closed

environment with little- oxygen. This causes the substance-s to break down into
different compounds.

Plastic waste- can be turned into fuel through pyrolysis. The- plastic is
exposed to extre-me heat without oxygen, with a catalyst he-lping to gently break
the long chains. The- gases created are- cooled and become oil with low sulfur
le-vels. Catalysts stop dioxins and furans from forming during this process.
Making gasoline and diesel from plastic waste efficiently requires optimizing
factors like the specific catalysts used, pyrolysis temperature. Using co-pyrolysis

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of plastic with coal the quality of crude oil can be improved. Due to which
viscosity of crude oil produced is reduced.

The key things pyrolysis makes are this: An oil full of hydrocarbons. Its
heating power at 25–45 MJ/kg fits for powering processes. A gas that can fuel the
process. And some char. The oil can swap in for diesel fuel. But only if it costs
under 85% of regular diesel. It has to perform and give energy like diesel, too.
However, the oil made from plastics often has more sulfur than normal fuel oil.
So the gas from pyrolysis can be cycled back into the process for heating. This
cuts need for external heating sources a lot.

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 METHODOLOGY

1. Collection:

The first step in converting the waste plastics to oil is the collection of
plastic waste. Various sources that can be targeted for plastic waste collection
include residential, commercial, and industrial settings. That is, plastics such
as pure PP/PE/PS/ABS plastics, pure white plastic sheets, food packing bags,
paper-mill waste, plastic household waste, and aluminum plastic medical
waste should be the main collection objects.

2. Shredding: (Optional)
This step can be taken if highly efficient and continuous pyrolysis is
required. In other words, DOING continuous plastic to oil pyrolysis machine
needs to perform this step, but batch type does not. The plastics go through a
shredding process to reduce them into smaller pieces, which is easy to feed and
increases efficiency.

3. Pyrolysis:
This step involves the degradation of the plastic waste in the absence of
oxygen. Waste plastics are mainly composed of long molecular chains that break
down into short molecular chains, that is the oil-gas and carbon black upon
heating at high temperatures.

There are various kinds of pyrolysis procedures termed slow, fast, flash,
and catalytic plastic pyrolysis depending upon the temperature range,
chemicals used and the heating rate of the process being carried out. Amongst
these fast and flash pyrolysis facilitates the formation of higher
concentrations of liquid products, oils, and similar lighter components.

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Catalytic Pyrolysis: This technique uses a suitable catalyst for carrying out the
thermal degradation which enables the pyrolysis process to occur at milder
conditions in a short duration of time which increases the efficiency of the
process and enables the formation of oil with a high RON value (Research
Octane Number).

FC
Gases

Cooling water FC
1

TC
FC FC

2 1 -- Transportation
2 -- Selective collection Gasoline
3 -- Shredding
4 -- Washing
5 -- Drying
6 -- Waste storage
3 7 -- Catalyst storage Light oil
4 8 -- Reactor
9 -- Heating gas storage
10 -- Separation unit 10
11 -- Catalyst filter
6
7
5

8
FC Catalyst

VC
9 TC
Heavy
oil
11

Pre-treatment Separation
Pyrolysis

Fig. Process Flow diagram

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4. Condensation:

The next step is cooling down the oil-gas to the liquid oil and non-
condensable gas in the condenser system. This oil is pyrolysis oil, which is a kind
of heavy oil and can be used as a fuel for industrial plants. The non-condensable
gas phase consists of hydrocarbon compounds, including methane flammable
gas, which can be used as pyrolysis fuel or for other heating purposes.

5. Distillation:

The fuel oil can be further processed by the distillation plant and
then can be refined into gasoline and diesel fuels. This diesel fuel can be
used for power generation or agricultural diesel engines.

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 RESULTS AND DISCUSSIONS

Plastics are crucial items used everywhere. They get formed into all kinds
of products. Their mechanical and chemical properties make them perfect for
packaging, cars, and electronics. Plastics are inexpensive, light, and tough. That's
why people shape them into countless products globally. We make more and
more plastics each year. Their low costs and flexibility drive widespread use.
Discarded plastic can be transformed into fuel that can substitute fossil
fuels. Facilities have been set up in different countries to convert waste plastic
into hydrocarbon fuel through a process called pyrolysis. This provides a cost-
effective and alternative solution to traditional petroleum.
The use of pyrolysis to create oil from plastic waste offers both
environmental and financial benefits over other options. This approach helps
combat pollution and reduces our reliance on traditional oil sources, which are
being depleted. By utilizing pyrolysis, we can lessen our dependence on
conventional oil.
This process acts as an alternative raw material in the production of
petroleum-based products and lubricants. Overall, this technology helps reduce
plastic waste and lower oil import expenses for countries that lack their own oil
reserves.

The products of pyrolysis of waste plastics are oil, charcoal, syngas,

condensable gas, water and ash. The gases produced through this process consist
hydrogen, Carbon Dioxide, Methane, CO, C2H4, C4H6, n-butane and other
miscellaneous hydrocarbon. The primary outcome of the pyrolysis process is the
production of oil from waste plastics. Waste. At temperature 330∘ C around
38.5% of WPPO was obtained. And this obtained oil percentage increased to 76%
at 425∘ C. The yield of oil varies depending on several factors, including the type
of plastic feedstock, operating conditions like (temperature, residence time,
heating rate), and the pyrolysis reactor design. Generally, polypropylene (PP),
high-density polyethylene (HDPE) and Polystyrene (PS) exhibit higher oil yields
compared to polyvinyl chloride (PVC) and LDPE because HDPE and PP have
relatively simple and linear molecular structures composed predominantly of

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carbon and hydrogen atoms consisting of long chains of repeating monomer
units.
This structural simplicity and regularity of HDPE and PP make them more
conducive to thermal decomposition during pyrolysis compared to more
complex polymers also due to Lack of Branching, Lower Contaminant Content
and Stability and Thermal Resistance (HDPE and PP possess relatively high
thermal stability, meaning they can withstand elevated temperatures without
undergoing significant degradation or decomposition. This thermal resistance
allows them to undergo pyrolysis at higher temperatures, resulting in increased
oil yields. Other plastics with lower thermal stability may degrade or undergo
undesirable side reactions at elevated temperatures, reducing the overall yield of
valuable products). We obtain more char in thermal pyrolysis compare to the
catalytic pyrolysis. Also yield of liquid fuel is more in catalytic pyrolysis than the
thermal pyrolysis.
Waste plastic pyrolysis oil investments rises. Usage also grows. It reduces
need for fossil fuels. Plastic waste pyrolysis plays an important part.

VISCOSITY: - Viscosity depends on feedstock, temperature, pyrolytic conditions

and other parameters. If the viscosity is higher than engine temperature, fuel
consumption and load on the engine will also be high. Whereas it may cause
more friction when the viscosity of oil is too high. Viscosity of pyrolysis oil is
lower than diesel and higher than kerosene at 40∘C

DENSITY: - The density of fuel oil is an essential property. There will be less
consumption of fuel if it has high density. On the other hand, fuel consumption
will be low for low density, it can damage the engine. The oil created through
pyrolysis has a density similar to diesel, kerosene, and gas oil. This suggests the
oil from plastic pyrolysis could potentially serve as a replacement for these
traditional fuels.
FLASH POINT: - Pyrolysis waste plastic oil has an unpredictable flash point. It
can change based on the oil's composition and the particular pyrolysis method
which will be used. A low flash point signals highly flammable materials are
present in the fuel. This raises major safety worries when handling or
transporting it.

CALORIFIC VALUE: - WPPO fuel has a lower calorific value compared to

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conventional diesel fuel. Calorific value of WPPO is close to the calorific value of
conventional oil.

FIRE POINT: - At low-temperature conditions how oil is behaving is determine

by Fire point. It is less suitable to use WPPO in cold weather if it has low fire
point.
waste plastic pyrolysis oil has fire point nearly to 35-36 °C.

Figure 1: Density of different types of fuel. Figure 2: Flash point of different oil.

PROPERTIES WPPO DIESEL FURNACE OIL KEROSENE

DENSITY (g/cc at 40°C) 0.7477-0.7943 0.85 0.8 to 0.95 0.78 to 0.82

FLASH POINT (°C) 20 to 32 52 to 93 66 to 93 37 to 65

(-18) to (-
POUR POINT (°C) (-17) 40) (-9) to (-21) (-40) to(-50)
FIRE POINT (°C) 35 to 36 60 to 96 66 to 99 38 to 72
CALORIFIC VALUE
(MJ/KG) 43.175 45.5 38 to 41 42 to 46
*WPPO- WASTE PLASTIC PYROLYTIC OIL
(Table 1: collected from google)

The pyrolytic oil has a tremendously decrease flash factor usually in between 10
to 40° C against 50° C for business diesel. Business diesel shows that pyrolytic oil
consists of high volatility cloth, that's volatile than traditional fossil fuels. In
comparison to traditional gasoline Sulphur content material is higher in the oil

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produced from plastic wastes.
For enhancing the first-rate of the pyrolytic oil SO2 and HCl purifiers are
required for the elimination of significant impurities like the SO2 and HCl vapors
from the recovered oil. Due to the oxide emissions from Sulphur content material
present in pyrolysis causes acid rain. Sulphur content is more in pyrolysis oil
than the conventional fuels like kerosene, diesel etc. In a standard case, the
Sulphur content present in the WPPO is 0.256% and Sulphur content in the
diesel oil and gasoline is 0.16%, 0.015% respectively. Thermal pyrolysis emits
4.79% material which have Sulphur when mixed with plastic.
The main products obtained from pyrolysis of plastic are the oil and
hydrocarbon rich gasoline. It has heating value of 25– 40 MJ/kg. We can use it
for process strength restoration and char. To reduce the dependance on external
heating sources the gas which is produced during pyrolysis can be used again. It
was determined that the gas produced through the pyrolysis process is of high
quality, sharing properties similar to diesel fuel. It requires minimal adjustments,
such as fine-tuning the fuel injection timing in diesel engines, to achieve optimal
efficiency.
The pyrolysis oil can be utilized for various purposes, such as for powering
gas turbines, producing gasoline, and supplying aviation and jet propulsion
systems. The pyrolysis oil may be suitable for many programs like lubrication oil
production, gasoline for boilers, and plastic feedstock manufacturing by using
combined pyrolytic oil with diesel in appropriate ratios.
Although pyrolysis process can mitigate plastic pollution by converting
waste plastic into useful products, the process itself may emit pollutants and
greenhouse gases, if not properly operated in controlled way. Emissions such as
volatile organic compounds (VOCs) and particulate matter causes air pollution
and that causes negative health effects. The process of pyrolysis requires
significant energy input in the form of heat, to break down the plastic polymers
into hydrocarbon products. Different types of plastics can yield varying quality of
pyrolysis oil, and contamination from non-plastic materials can affect the output.
Ensuring consistent feedstock quality and minimizing contaminants is essential
for producing high-quality pyrolysis oil.

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 Conclusion

Finally, the process of changing waste plastics into oil through pyrolysis
will provide a way out of energy and environmental problems. The findings and
discussions reveal that this method can help deal with plastic waste
accumulation while giving rise to a valuable source of hydrocarbon fuel.
Pyrolysis transforms plastics into oil, syngas, and char which are a good
alternative for non- renewable fossil fuels. The high oil yields obtained from
plastics such as HDPE and PP demonstrate how useful resources can be extracted
from waste through this way. Additionally, the resulting pyrolysis oil has similar
qualities to conventional fuels hence it is appropriate for different areas like
transportation as well as industrial processes.

However, one must recognize and deal with the challenges posed by
diversity in feedstock, contamination and emissions during this pyrolysis
process. To achieve environmental sustainability and ensure quality products,
optimization of pyrolysis technologies should be pursued, purification methods
to remove impurities from oil should be employed while enhancing process
efficiency. Furthermore, a circular economy is supported through the
encouragement of appropriate waste disposal approaches and creating public
awareness on plastic recycling and pyrolysis hence breaking away from finite
fossil fuel reliance.

In summary plastic waste pyrolysis provides an avenue for managing

plastic waste while boosting energy security as well as environmental
conservation. By capitalizing on this technology’s potentials to overcome its
problems we can steer towards a cleaner more sustainable future.

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