EXTRACTION OF BIODIESEL FROM PLASTIC WASTE

MATERIAL

A PROJECT REPORT

submitted by

ABHIJITH BALAKRISHNAN (KIT20ME001)

MIDHUN J NAIR (KIT20ME006)

RAHUL K A (KIT20ME007)

to

the APJ Abdul Kalam Technological University

in partial fulfillment of the requirements for the award of the Degree
of

Bachelor of Technology

In

Mechanical Engineering

Department of Mechanical Engineering

Kottayam Institute of Technology and Science
Chengalam East P.O, Pallickathode, Kottayam, Pin. 686585
 April 2024
DEPARTMENT OF MECHANICAL ENGINEERING
KOTTAYAM INSTITUTE OF TECHNOLOGY AND SCIENCE,
CHENGALAM

This is to certify that the project report entitled “EXTRACTION OF

BIODIESEL FROM PLASTIC WASTE MATERIAL” submitted by

ABHIJITH BALAKRISHNAN, MIDHUN J NAIR, RAHUL K A to the APJ Abdul
Kalam Technological University in partial fulfillment of the requirements for the award
of the Degree of Bachelor of Technology in Mechanical engineering is a bonafide
record of the project work carried out by him under my supervision and guidance. This
report in any form has not been submitted to any other University or Institute for any
purpose.

Internal Supervisor External Supervisor

Mr. Nirmal K Noble
Assistant Professor
Dept. of Mechanical Engineering
Kottayam Institute of Technology and
Science,
Chengalam.

Project Coordinator HEAD OF THE DEPT (In Charge)

Mr. Gokul S Kumar Mr. Nirmal K Noble
Assistant Professor Assistant Professor
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
Kottayam Institute of Technology and Kottayam Institute of Technology and
Science, Science,
Chengalam Chengalam.

Place: Chengalam
Date: 10/04/2024
 DECLARATION
I undersigned hereby declare that the project report “EXTRACTION OF BIODIESEL
FROM PLASTIC WASTE MATERIAL”, submitted for partial fulfillment of the
requirements for the award of degree of Bachelor of Technology of the APJ Abdul Kalam
Technological University, Kerala is a bonafide work done by me under supervision of
Mr.Nirmal K Noble. This submission represents my ideas in my own words and where
ideas or words of others have been included, I have adequately and accurately cited and
referenced the original sources. I also declare that I have adhered to ethics of academic
honesty and integrity and have not misrepresented or fabricated any data or idea or fact or
source in my submission. I understand that any violation of the above will be a cause for
disciplinary action by the institute and/or the University and can also evoke penal action
from the sources which have thus not been properly cited or from whom proper
permission has not been obtained. This report has not been previously formed the basis
for the award of any degree, diploma or similar title of any other University

Place: Chengalam ABHIJITH BALAKRISHNAN

MIDHUN J NAIR
Date: 10/04/2024
RAHUL K A
 ACKNOWLEDGEMENT

Dedicating this to the almighty God whose abundant grace and mercies enabled its
successful completion, I would like to express my profound gratitude to all the people
who have inspired and motivated us to make this seminar a success.

I am extremely grateful to our principal, Dr. Deepa S R, our Dean , Dr P Arun Bose,
and our HOD, Mr. Nirmal K Noble, Department of Mechanical Engineering, Kottayam
Institute of Technology and Science, Chengalam. for their valuable suggestions and
encouragement that was a constant source of inspiration and motivation for during the
course of this project.

I am very much thankful to our project Coordinator Mr. Gokul S Kumar, Assistant
Professor, Department of Mechanical Engineering, Kottayam Institute of Technology
and Science, Chengalam, for their helpful hands during my project.

I deem the privilege of thanking my project Guide Mr. Nirmal K Noble, Assistant
Professor, Department of Mechanical engineering, Kottayam Institute of Technology
and Science, Chengalam, for his constant help, creative ideas, valuable advice, and
guidance rendered us through the course of this project.

My profound gratitude to all staff, for their valuable guidance, kind cooperation, and
help provided for the successful completion of this project.

1
 ABSTRACT

There is an increase in the production and consumption of plastics as the day go by. All
plastics need to be disposed after their usefulness, as waste. The needs to manage this
waste from plastic become more apparent. This leads to pyrolysis, which is a way of
making to become very useful to us by recycling them to produce fuel oil. In this study,
plastic wastes (polyethylene) were used for the pyrolysis to get fuel oil that has the same
physical properties as the fuel used in aviation industry (JP-4). The experiment was
carried out in such a way on, thermal pyrolysis (without the aid of a catalyst). Some of the
plastics wastes that are suitable for pyrolysis are: HDPF (high density polyethylene).

Thus the problems faced by the increasing in plastic waste and the increasing fuel crisis
can be eliminated by making a system which can decrease the pollution due to plastic and
increasing the availability of the alternative fuel. This work aims to fabricate a system
which converts plastic waste into biodiesel. This was made by converting the waste
plastic into useful alternative oil by means of pyrolysis process.

Keywords: Pyrolysis,Biodiesel,HDPF.

2
 CONTENTS
Contents Page No
ACKNOWLEDGEMENT i
ABSTRACT ii
LIST OF FIGURES v
LIST OF TABLES v
Chapter 1 INTRODUCTION 1

1.1. Overview and background 2

1.1.1. Plastics 2
1.1.2. Target Waste Plastics 3

Chapter 2 LITERATURE REVIEW 7

2.1. Introduction 7

2.2. Literature review 7

2.3. Summary of the literature survey 9

Chapter 3 OBJECTIVES AND METHODOLOGY 10

3.1. Objectives 10
3.2. Methodology 10

Chapter 4 TYPES OF PLASTIC 11

Chapter 5 PYROLYSIS TECHNIQUE 12

5.1. Specimen dimension 12

5.2. Pyrolysis oil 12

5.3. Pyrolysis oil characteristics 13

5.4. Advantages of pyrolysis process 13

Chapter 6 COMPONENTS AND DESCRIPTION 14

3
 6.1. Low density polyethylene 14

6.2. Reactor 14

6.3 Furnace 15

6.4 Condenser 15

6.5 Copper tube 16

6.6 Heating element 16

Chapter 7 MANUFACTURING PROCESS 17

7.1 Metal cutting 17

7.2 Sawing 18

7.3 Welding 18

7.4 Drilling 19

7.5 Inspection 20

7.6 Assembly 20

Chapter 8 WORKING PRINCIPLE 21

Chapter 9 ADVANTAGES & DISADVANTAGES & 22

APPLICATIONS

Chapter 10 LIST OF MATERIALS 23

Chapter 11 COST ESTIMATION 24

11.1 Material Cost 24

11.2 Labour Cost 25

11.3 Overhead Cost 25

Chapter 12 RESULTS 26

Chapter 13 CONCLUSION 27

Chapter 14 REFERENCE 28

4
 LIST OF FIGURES

Figure Title Page No

5.1 Pyrolysis process 12
6.2 Reactor 14
6.3 Furnace 15
6.4 Condenser 16
6.5 Copper tube 16
7.1 Manufacturing process 17
7.2 Welding 19
7.3 Drilling 19
8.1 2D view of apparatus 21

LIST OF TABLES

2.1 Polymer as feedstock for fuel production 5

2.2 Product types of some plastic pyrolysis 6

5
 CHAPTER 1
INTRODUCTION
The consumption of plastics has increased from 4000 tons/annum (1990) to 4 million
tons/annum (2001) and it is expected to rise 8 million tons/annum during the year
2009.Nearly 50 to 60% of the total plastics are consumed for packing. Once used plastic
materials are thrown out. They do not undergo bio-decomposition. Hence, they are either
land filled or incinerated. Both are not eco-friendly processes as they pollute the land and
the air. Waste tyres in India are categorized as solid waste or hazardous waste. It is
estimated that about 60% of (retreated) waste tyres are disposed via unknown routes in
the urban as well as rural areas. The hazards of waste tyres include- air pollution
associated with open burning of tyres (particulates, odour, visual impacts, and other
harmful contaminants such as polycyclic aromatic hydrocarbon, dioxin, furans and oxides
of nitrogen), aesthetic pollution caused by waste tyre stockpiles and illegal waste tyre
collecting and other impacts such as alterations in hydrological regimes when gullies and
watercourses become waste sites.

Plastics have now become indispensable materials, and the demand is continually
increasing due to their diverse and attractive applications in households and industries.
Mostly, thermoplastics polymers make up a high proportion of waste, and this amount is
continuously increasing around the globe. Hence, waste plastics pose a very serious
environmental challenge because of their huge quantity and disposal problem as
thermoplastics do not biodegrade for a very long time. All the reasoning and arguments
for and against plastics finally land upon the fact that plastics are nonbiodegradable. The
disposal and decomposition of plastics have been an issue that has caused several types of
research works to be carried out in this regard. Currently, the disposal methods employed
are landfilling, mechanical recycling, biological recycling, thermal recycling, and
chemical recycling. Of these methods, chemical recycling is a research field which is
gaining much interest recently, as it turns out to be that the products formed in this
method are highly advantagous.

1
1.1. OVERVIEW AND BACKGROUND
1.1.1. PLASTICS
Plastics are polymeric materials, a material built up from long repeating chains of
molecules. Polymers such as rubber occur naturally, but it wasn’t until the development
of synthetic polymers around 1910 that the polymers tailored to the needs of the engineer
first started to appear. One of the first commercial plastics developed was Bakelite and
was used for the casting of early radios. Because the early plastics were not completely
chemically stable, they gained a reputation for being cheap and unreliable. However,
advances in plastic technology since then, mean that plastics are a very important and
reliable class of materials for product design.

Plastic is a marvel of polymer chemistry, plastics have become an indispensable part of

our daily life. But repeated reprocessing of plastic waste, and its disposal cause
environmental problems, pose health hazards, in addition to being a public nuisance. The
biggest current threat to the conventional plastics industry is likely to be environmental
concerns, including the release of toxic pollutants, greenhouse gas and non-biodegrable
landfill impact as a result of the production and disposal of petroleum based plastics.

In 1961, the patent for carbon fiber was filed; it provided the high stiffness to weight ratio
to the composite. Carbon fibers based composites were used in automobile, aerospace,
consumer goods and sports industry. In between 1970s and 1980s, the high molecular
weight polyethylene was developed and used in aerospace, marine and sports industries.
During 1990s and 2000s, the composite was the main stream material in the
manufacturing industries as it was used in home appliances and industrial uses. In
industry, the composite was mainly used in place of conventional material for weight
reduction with better strength to weight ratio.

Plastics are inexpensive, lightweight, strong, durable, corrosion-resistant materials, with

high thermal and electrical insulation properties. The diversity of polymers and the
versatility of their properties are used to make a vast array of products that bring medical
and technological advances, energy savings and numerous other societal benefits. As a
consequence, the production of plastics has increased substantially over the last 60 years
from 0.5 million tonnes in 1950 to over 260 million tonnes today. In Europe alone the
plastics industry has a turnover in excess of 300 million euros and employs 1.6 million
people. Almost all aspects of daily life involve plastics, in transport, telecommunications,

2
clothing, footwear and as packaging materials that facilitate the transport of a wide range
of food, drink and other goods. There is considerable potential for new applications of
plastics that will bring benefits in the future, for example as novel medical applications, in
the generation of renewable energy and by reducing energy used in transport.

Some plastics wastes are suitable for pyrolysis such as: HDPE (high density
polyethylene), LDPE (low density polyethylene), polypropylene' polystyrene' polyvinyl
alcohol, polyoxy-methylene, polyamide, polyurethane, polyphenylene, polyvinyl chloride
etc. But for tire pupose of this study low density polyethylene (LDPE) was used since it is
Commonly found littered around our environment' Polyethylene is an excellent source of
hydrocarbon products. It is highly resistant to thermal degradation, requiring a
temperature of above 400oC in order to exhibit sufficiently high degradation rates. The
high temperature causes the loss of selectivity, increased secondary reactions, coke
formations and reduced catalyst life.

1.1.2. TARGET WASTE PLASTICS

Waste plastics are one of the most promising resources for fuel production
because of its high heat of combustion and due to the increasing availability in local
communities. Unlike paper and wood, plastics do not absorb much moisture and the water
content of plastics is far lower than the water content of biomass such as crops and
kitchen wastes.The conversion methods of waste plastics into fuel depend on the types of
plastics to be targeted and the properties of other wastes that might be used in the process.
Additionally the effective conversion requires appropriate technologies to be selected
according to local economic, environmental, social and technical characteristics.

In general, the conversion of waste plastic into fuel requires feedstocks which are
non-hazardous and combustible. In particular each type of waste plastic conversion
method has its own suitable feedstock. The composition of the plastics used as feedstock
may be very different and some plastic articles might contain undesirable substances (e.g.
additives such as flame-retardants containing bromine and antimony compounds or
plastics containing nitrogen, halogens, sulfur orany other hazardous substances) which
pose potential risks to humans and to the environment.

The types of plastics and their composition will condition the conversion process and will
determine the pretreatment requirements, the combustion temperature for the conversion
and therefore the energy consumption required, the fuel quality output, the flue gas

3
composition (e.g. formation of hazardous flue gases such as NOx and HCl), the fly ash
and bottom ash composition, and the potential of chemical corrosion of the equipment,
Therefore the major quality concerns when converting waste plastics into fuel resources
are as follows:

1) Smooth feeding to conversion equipment: Prior to their conversion into fuel

resources, waste plastics are subject to various methods of pre-treatment to
facilitate the smooth and efficient treatment during the subsequent conversion
process. Depending on their structures (e.g. rigid, films, sheets or expanded
(foamed) material) the pre-treatment equipment used for each type of plastic
(crushing or shredding) is often different.
2) Effective conversion into fuel products: In solid fuel production, thermoplastics
act as binders which form pellets or briquettes by melting and adhering to other
non-melting substances such as paper, wood and thermosetting plastics. Although
wooden materials are formed into pellets using a pelletizer, mixing plastics with
wood or paper complicates the pellet preparation process. Suitable heating is
required to produce pellets from thermoplastics and other combustible waste. In
liquid fuel production, thermoplastics containing liquid hydrocarbon can be used
as Feedstock. The type of plastic being used determines the processing rate as well
as the product yield. Contamination by undesirable substances and the presence of
moisture increases energy consumption and promotes the formation of by
products in the fuel production process.
3) Well-controlled combustion and clean flue gas in fuel user facilities: It is
important to match the fuel type and its quality to the burner in order to improve
heat recovery efficiency. Contamination by nitrogen, chlorine, and inorganic
species, for instance, can affect the flue gas composition and the amount of ash
produced. When using fuel prepared from waste plastics, it must be assured that
the flue gas composition complies with local air pollution regulations. In the same
way, ash quality must also be in compliance with local regulations when disposed
at the landfill. If there aren’t any relevant regulations, both the producers and
consumers of the recycled fuel should control the fuel quality and the emissions at
combustion in order to minimize their environmental impact.

4
 Table 2.1. Polymer as feedstock for fuel production

Types of polymer Description Examples

Polymers consisting of Typical feedstock Polyethylene,polypropylene,polystyrene.

carbon and hydrogen. for fuel production Thermoplastics melt to form solid fuel
due to high heat mixed with other combustible wastes and
value and clean decompose to produce liquid fuel.
exhaust gas.

Polymers containing Lower heat value PET,phenolic resin,polyvinyl

oxygen. than above plastics. alcohol,polyphenylene sulfide.

Polymers containing Fuel from this type Nitrogen:polyamide,polyurethane

nitrogen or sulfur. of plastic is a source Sulfur:polyphenylene sulfide
of hazardous
components such as
NOx or SO in flue
gas .Flue gas
cleaning is required
to avoid emission of
hazardous
components in
exhaust gas.

Polymers containing Source of hazardous Polyvinylchloride,polyvinylidene chloride

halogens of and corrosive flue ,bromine-containing flame retardants and
chlorine,bromine and gas upon thermal fluorocarbon polymers.
fluorine. treatment and
combustion.

5
 Table 2.2. Product types of some plastic pyrolysis

Main products Type of plastics As a feedstock of liquid

fuel
Liquid hydrocarbons Polyethylene(PE) Allowed
Polypropylene(PP) Allowed
Polystyrene(PS) Allowed
Polymethyl metacrylate(PMMA) Allowed
Liquid hydrocarbons Acrylonitrile-butadiene-styrene Allowed But not
copolymer(ABS) suitable
Nitrogen-containing fuel
is obtained.
Special attention required
to cyanide in oil
No hydrocarbons Polyvinyl alcohol(PVA) Not suitable.Formation of
suitable for fuel water and alcohol
Not suitable.Formation of
Polyoxymethylene (POM) formaldehyde
Solid products Polyethylene terephthalate Not suitable Formation of
(PET) terephthalic acid and
benzoic acid
Carbonous products Polyurethane (PUR) Not suitable
Phenol resin (PF)
Not suitable
Hydrogen chloride and Polyvinyl chloride (PVC) Not allowed
carbonous products Polyvinylidene chloride(PVDC)
Not allowed

6
 CHAPTER 2
LITERATURE REVIEW

2.1. INTRODUCTION
Several research reports are available in the literature about extraction of biofuel from
plastic. This chapter covers the various studies carried out on biofuels .

2.2. LITERATURE REVIEW

Faisal et.al[1]. reviewd This study reviews the performance, emissions, and combustion
characteristic of diesel engines fuelled with neat Plastic pyrolytic oil(PPO), PPO and
diesel blends, and PPO with oxygenated additives. PPO has higher viscosity and density,
higher sulphur content, lower flash point, lower cetane index and an unpleasant odour.
PPO displays a higher delay in ignition during the premixed combustion phase. It found
that brake specific fuel consumption can be lowered by 17.88 % by using neat PPO in the
engine. Brake thermal efficiency can be reduced by 17.26%while blends of PPO and
diesel are used. Some studies say NOx emission can be reduced up to 63.02 %, however,
others indicate that it can be increased up to 44.06 % compared to diesel when PPO is
used in engines. The highest reduction in CO2 emission was found to be 47.47 % using
blends of PPO and diesel; conversely, the highest increase was documented as 13.04 %
when only PPO is used as fuel. In summary, PPO has very high potential as a substitute
for commercial diesel fuel through further research and by improving its properties
through posttreatment.

Srinivas et.al[2] used , plastic waste as a source for the production of automotive bio-
diesel fuel via a two-step thermochemical process based on pyrolysis and hydro-
treatment. As many environmental and social problems arise from plastic waste, re-use
technologies are of vital importance in achieving the Sustainable Development Goals
(SDG). A potentially cost-effective solution can be accomplished by using waste

Giridarshan et.al[3] used pyrolysis to heating substance plastics processed into bio-oil.
Thus, the problems faced by the rise in plastic waste and the rising fuel crisis can be

7
avoided by developing a system that can minimize hydrocarbons dependence due to
plastics and increase the availability of alternative fuels.in the absence of oxygen that
dissolves all these type of waste plastic. The heating temperature should be around 450 0C.
In this study, paralysis process is used to attain the required temperature, where all the
types of waste plastic is being converting to fuel. It works like other fuels like petrol,
diesel, and kerosene. By implementing this concept, some amount of waste plastic can be
reduced (about 70-80% of waste plastic) and can roughly provide about 50% oil for diesel
vehicles. Tests have shown that this fuel does not emit sulfur dioxide and generates about
5% residue as carbon block. n this study, paralysis process is used to attain the required
temperature, where all the types of waste plastic is being converting to fuel

Karlsson et.al[4] is assessed, pyrolysis of plastic waste against MR, municipal solid waste
incineration (MSWI) and fuel substitution through climate footprint assessment (CFA)
based on primary data from pyrolysis of plastic waste sourced from Danish waste
producers. Results of the CFA are scaled to the Danish plastic waste resource in an
impact assessment of current Danish plastic waste management, and scenarios are
constructed to assess reductions through utilization of pyrolysis. Results of the CFA show
highest benefits utilizing pyrolysis for monomer recovery (1400 and 4800 kg CO 2 per ton
polystyrene (PS) and polymethyl methacrylate (PMMA), respectively) and MR for single
polymer polyolefins (1000 kg CO2 per ton PE). The two management options perform
similarly with mixed plastic waste (200 kg CO 2 per ton plastic waste). MSWI has the
highest impact (1600–2200 kg CO2 per ton plastic waste) and should be avoided when
alternatives are available. Scaling the results of the CFA to the full Danish plastic waste
resource reveals an impact of 0.79 Mt CO2 in year 2020 of current plastic waste
management. Utilizing pyrolysis to manage MR residues reduces the system impact by
15%. Greater reductions are possible through increased separation of plastic from residual
waste. The best performance is achieved through a combination of MR and pyrolysis.

Wenfei et.al[4] studied the effect of clay as the catalyst on mixed plastic pyrolysis for fuel
and energy recovery. Four kinds of clay, including nanoclay, montmorillonite, kaolin, and
hydrotalcite, were used as catalysts for the pyrolysis of mixed plastic consisted of
polyethylene terephthalate, polystyrene, polypropylene, low-density polyethylene, and
high-density polyethylene. The product yield and distribution varied with different clay in
pyrolysis. The highest yield of oil was 71.0 % when using montmorillonite as the catalyst.
While the highest contents of gasoline range hydrocarbons and diesel range hydrocarbons

8
in the oil were achieved when using kaolin and nanoclay, respectively as catalysts. For
the gas products, the CO, C2H4, C2H6, C3H6, and C4H10 increased with decreased CO2 in
the gaseous products when using clay as catalysts. In general, the mild acidity of clay
catalyst was essential to improve the oil yields and the proportion of the gasoline or diesel
range fuels in the catalytic pyrolysis of mixed plastic waste.

2.3. SUMMARY OF LITERATURE SURVEY

Based on literature survey following conclusion are made

• Variety of raw materials can be used for the production of biofuel.

• Out which, Low density polyethylene found to be more suitable for the production
of biofuel

• Pyrolysis can used to convert plastic into biofuel

9
10
 CHAPTER 3
OBJECTIVES AND METHODOLOGY
This project attempts to show how human has been utilizing the energy and explore
prospects of optimizing the same one of the alternative fuels is household plastic waste
oil. Fuel obtained from pyrolysis process shows nearly same properties as that of diesel
fuel. So we can use plastic oil as alternative fuel.

OBJECTIVES
● To collect the household plastic waste from different places.
● To develop and fabricate the pyrolysis unit to produce liquid fuel from plastic
waste.
● Conversion of household plastic waste in to liquid fuel.
● To purify the produced liquid fuel by water washing method.
● To conduct the different experiments to determine the different properties of
liquid fuel.

METHODODLOGY
• Selection of suitable raw materials.
• Fabrication of apparatus for production of biodiesel
• Production of biodiesel from fabricates apparatus.
• Testing the properties of biodiesel like calorific value, viscosity, flash point etc..
• Blending of biofuel with diesel

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 CHAPTER 4
TYPES OF PLASTIC
● TYPE 1 (PETE)
Polyethylene terephthalate. Soft drink and water bottles, some water proof packaging.
Commonly recycled.

● TYPE 2 (HDPE)
High density polyethylene. Milk, detergent, and oil bottles, toys and some plastic bags are
Commonly recycled.

● TYPE 3 (V)
Vinyl/polyvinyl chloride (PVC). Food construction materials, shower curtains. Not
additives and is known to off gas in the air wrap, vegetable oil bottles, recyclable, can
leach chemical.
● TYPE 4 (LDPE)

Low density polyethylene. Many plastic bags squeezable bottles, garment bags recycle at
most centers but not curbside programs.

TYPE 5 (PP)

Polypropylene. Refrigerated containers, sorne bags, most bottle tops, solne

carpets, some food wrap. Recycled at most centered but not curbside programs.

TYPE 6 (PS)

Polystyrene. Throwaway utensils, tneat packing, take out containers, protective

packing. Recycled at some centers but not curbside programs and banned in some cities.

TYPE 7 (OTHER)

Composite plastics, Nalgene bottles, milk cartons, toothpaste tubes.

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 CHAPTER 5
PYROLYSIS TECHNIQUE
5.1. SPECIMEN DIMENSIONS
Pyrolysis is chernical reactions in which large molecules are broken down into srnaller
molecules. Sirnplest example of pyrolysis is cooking in which complex food molecules
are broken down into smaller & easy to digestible molecules.Waste plastic and tire are
long chain molecules or polymer hydrocarbons. Pyrolysis technology is the industrial
process of breaking down large molecules of plastic/tire into smaller molecules of oil, gas
and carbon black. Pyrolysis of waste plastic or tire takes place in absence of oxygen, at
about 350-550 degree C and reaction time is about 15-90 minute.

Figure 5.1. Pyrolysis process

5.2. PYROLYSIS OIL

Pyrolysis oil is sorne times known as bio crude oil or bio oil, is a synthetic fuel under
investigation as substitute for petroleum. It is extracted by biornass to liquid technology
of destructive distillation from dried biornass in a reactor at a temperature of about 500
degree Celsius with subsequent cooling. Pyrolysis oil (bio oil) is a kind of tar and
normally contains too high level of oxygen to be a hydro carbon. As such is distinctly
different from similar petroleum products.

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5.3. PYROLYSIS OIL CHARACTERISTICS

The oil produced in a pyrolysis process is acidic, with a PH of 1.5-3.8. The acidity may
be lessened by the addition of readily available base components. Little work has been
done on the stability of bio oil acidity that has been altered with base components while
the exact composition of bio oil depends on the bio mass source and processing
conditions a typical composition is as falls water 20- 28 %, suspended solids and
pyrolytic lignin 22-36yo, hydroxyl-acetaldehyde 8-120 , levoglucosan3-8o/o, acetic
acid4-8%, acetol 3 -6o/o, sellubiosonl-2%o, glycol 1-2 0/o, formic acid3-6. The water
molecules are split during pyrolysis and held separately in other compounds within the
complex with the pyrolysis liquid. The distinction is significant, as the "water" in
pyrolysis oil does not separate like standard fossil fuels.

5.4. ADVANTAGES OF PYROLYSIS PROCESS

● Air lock raw material feeding system with nitrogen purging: to prevent oxygen
entering into reactor.
● Lower reaction temperature of 350 to 475 degree C: Lower operating cost,
increased safety and reduced maintenance
● Step energy recovery system: to ensure energy efficiency of more than 80%.
● Energy self sufficient machinery: ensures more profits to investor & no of oil,
stable can be used to external fuel for heating required during normal operations
● Innovative catalyst combination: to ensure maximum yield reaction process
● Safe and automatic pyrolysis gas handling system: Excess gas run electricity
generator or can be supplied to furnace.
● Effective Scrubbing system: to ensure that emissions are well below limits
prescribed by environmental authorities.
● Multiple layers of safety: to prevent machinery damage or health hazards.

14
 CHAPTER 6
COMPONENT AND DESCRIPTION
The major parts “EXTRACTION OF FUEL FROM WASTE PLASTIC” are described
below:

● Low Density Polyethylene,

● Reactor,
● Furnace,
● Condenser,
● Copper tubes,Heating element.
6.1. LOW DENSITY POLYETHYLENE
This is prepared by high pressure of ethylene. It is made from petroleum. It has a density
range of 0.910 - 0.940 g/cm3. It is not reactive at room temperature, except by strong
oxidizing agents and some solvents causing swelling. It can withstand temperatures of
80oC continuously and 95oC for a short time. LDPE is used for manufacturing various
containers, dispensing bottles, wash bottles, tubing, plastic bags for computer, and its
common use is in plastic bags.
6.2. REACTOR
This is a stainless steel tube of length 145mm, internal diameter 37mm, outer diameter 4l
mm sealed at one end and an outlet tube at the other end. The reactor is to be placed
inside the furnace for external heating with the raw material inside for internal heating.
The reactor is heated by electrical heating to temperature of about 500oC and more.

15
 Figure 6.2. Reactor
6.3. FURNACE
The furnace provides the heat the reactor needs for pyrolysis to take place, it has a
thermocouple to control the temperature. A furnace is a device used for high-temperature
heating.

Figure 6.3. Furnace

6.4.CONDENSER
It cools all the heated vapour coming out of the reactor. It has an inlet and outlet for cold
water to run through its outer area. This is used for cooling the vapour. The gaseous
hydrocarbons at a temperature of about 35O oC are condensed to about 30-35 oC. In
systems involving heat transfer, a condenser is a device or unit used to condense a
substance from its gaseous to its liquid state, by cooling it. In so doing, the latent heat is
given up by the substance, and will transfer to the condenser coolant. Condensers are
typically heat exchangers which have various designs and come in many sizes ranging
from rather small (hand-held) to very large industrial-scale units used in plant processes.
For example, a refrigerator uses a condenser to get rid of heat extracted from the interior
of the unit to the outside air. Condensers are used in air conditioning, industrial chemical
processes such as distillation, steam power plants and other heat .
.

16
 Figure 6.4. Condenser

6.5.HEATING ELEMENT
A heating element converts electricity into heat through the process of resistive or Joule
heat ing. Electric current passing through the element encounters resistance, resulting in
heating of the element. Unlike the Peltier Effect this process is independent of the
direction of current flow.
6.6.COPPER TUBES
Copper tubing is most often used for supply of hot and cold tap water, and as refrigerant
line in HVAC systems. There are two basic types of copper tubing, soft copper and rigid
copper. Copper tubing is joined using flare connection, compression connection, or
solder. Copper offers a high level of corrosion resistance, but is becoming very costly.

Figure 6.5. Copper Tube

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 CHAPTER 7

MANUFACTURING PROCESS
Manufacturing processes are the steps through which raw materials are transformed into a
final product. The manufacturing process begins with the creation of the materials from
which the design is made. These materials are then modified through manufacturing
processes to become the required part. Manufacturing processes can include treating
(such as heat treating or coating), machining, or reshaping the material. The
manufacturing process also includes tests and checks for quality assurance during or after
the manufacturing, and planning the production process prior to manufacturing.

Figure 7.1. Manufacuring Process

7.1. METAL CUTTING
Metal cutting or machining is the process of by removing unwanted material from a block
of metal in the form of chips. Cutting processes work by causing fracture of the material
that is processed. Usually, the portion that is fractured away is in small sized pieces,
called chips. Common cutting processes include sawing, shaping (or planning),
broaching, drilling, grinding, turning and milling. Although the actual machines, tools and
processes for cutting look very different from each other, the basic mechanism for
causing the fracture can be understood by just a simple model called for orthogonal
cutting.

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In all machining processes, the work piece is a shape that can entirely cover the final part
shape. The objective is to cut away the excess material and obtain the final part. This
cutting usually requires to be completed in several steps – in each step, the part is held in
a fixture, and the exposed portion can be accessed by the tool to machine in that portion.
Common fixtures include vise, clamps, 3-jaw or 4-jaw chucks, etc. Each position of
holding the part is called a setup. One or more cutting operation may be performed, using
one or more cutting tools, in each setup. To switch from one setup to the next, we must
release the part from the previous fixture, change the fixture on the machine, clamp the
part in the new position on the new fixture, set the coordinates of the machine tool with
respect to the new location of the part, and finally start the machining operations for this
setup.

7.2. SAWING
Cold saws are saws that make use of a circular saw blade to cut through various types of
metal, including sheet metal. The name of the saw has to do with the action that takes
place during the cutting process, which manages to keep both the metal and the blade
from becoming too hot. A cold saw is powered with electricity and is usually a stationary
type of saw machine rather than a portable type of saw. The circular saw blades used with
a cold saw are often constructed of high speed steel. Steel blades of this type are resistant
to wear even under daily usage. The end result is that it is possible to complete a number
of cutting projects before there is a need to replace the blade. High speed steel blades are
especially useful when the saws are used for cutting through thicker sections of metal.
Along with the high speed steel blades, a cold saw may also be equipped with a blade that
is tipped with tungsten carbide. This type of blade construction also helps to resist wear
and tear. One major difference is that tungsten tipped blades can be re-sharpened from
time to time, extending the life of the blade. This type of blade is a good fit for use with
sheet metal and other metallic components that are relatively thin in design.

7.3.WELDING
Welding is a process for joining similar metals. Welding joins metals by melting
and fusing 1, the base metals being joined and 2, the filler metal applied. Welding
employs pinpointed, localized heat input. Most welding involves ferrous-based metals

19
such as steel and stainless steel. Weld joints are usually stronger than or as strong as the
base metals being joined.
Figure 7.2. Welding Process

7.4. DRILLING

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of
circular cross-section in solid materials. The drill bit is a rotary cutting tool, often
multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to
thousands of revolutions per minute. This forces the cutting edge against the workpiece,
cutting off chips (swarf) from the hole as it is drilled.

Figure 7.3. Drilling

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7.5. INSPECTION

Critical appraisal involving examination, measurement, testing, gauging, and comparison

of materials or items. An inspection determines if the material or item is in proper
quantity and condition, and if it conforms to the applicable or specified requirements.
Inspection is generally divided into three categories: (1) Receiving inspection, (2) In-
process inspection, and (3) Final inspection. In quality control (which is guided by the
principle that "Quality cannot be inspected into a product") the role of inspection is to
verify and validate the variance data; it does not involve separating the good from the
bad.

7.6. ASSEMBLY

An assembly line is a manufacturing process (most of the time called a progressive

assembly) in which parts (usually interchangeable parts) are added as the semi-finished
assembly moves from work station to work station where the parts are added in sequence
until the final assembly is produced. By mechanically moving the parts to the assembly
work and moving the semi-finished assembly from work station to work station, a
finished product can be assembled much faster and with much less labor than by having
workers carry parts to a stationary piece for assembly.

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 CHAPTER 8
WORKING PRINCIPLE
In our experiments, commercialize available shredded plastics were procured and washed
before pyrolysis. One of the most favorable and effective disposing method is pyrolysis,
which is environmental friendly and efficient way. Pyrolysis is the thermal degradation of
solid wastes at high temperatures (300oC-900oC) in the absence of air (and oxygen). As
the structure of products and their yields can be considerably modified by catalysts,
results of pyrolysis in the absence of catalyst were presented in this article Pyrolysis of
waste plastics was carried out in an indigenously designed and fabricated reactor.

Figure 8.1. 2D View of apparatus

Waste plastics had been procured form the commercial source and stored in a raw
material storage unit. Raw material was then fed in the reactor and heated by means of
electrical energy. The yield commenced at a temperature of 350 0C. The gaseous products
resulting from the pyrolysis of the plastic wastes is supplied through the copper tube.
Then the burned plastic gas condensed in a water cooled condenser to liquid fuel and
collected for experiments.

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 CHAPTER 9
ADVANTAGES AND DISADVANTAGES &
APPLICATIONS
ADVANTAGES
● Corrosion is less.

● No need of engine modification.

● Residue can be used as paraffin wax.

● Less amount of residue and large amount of product.

● Plastic wastes can be reduced.

● A proper solution for energy crisis.

● Can reduce the problems due to plastic wastes.

DISADVANTAGES

● Large amount of the fuel cannot be produced.

● Large amount of the input is needed.

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 CHAPTER 10
LIST OF MATERIALS

S. No. Description Qty Material

1 Frame Stand 1 Mild Steel

2 Reactor Tank 1 Mild Steel

3 Coupling Plates 2 Mild Steel

4 Heating Coil 1 Cu

5 Insulation Materials - Glass Wool

6 Copper Tubes 15 Feet Cu

7 Gate Valve 1 Mild Steel

8 Condenser Tank 1 Mild Steel

9 Waste Plastic 10Kg UPVC

10 Bolt and Nuts 20 M.S

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 CHAPTER 11
COST ESTIMATION
11.1. MATERIAL COST:-

S. Description Qty Material Cost (Rs)

No.

1 Frame Stand 1 Mild Steel

2 Reactor Tank 1 Mild Steel

3 Coupling Plates 2 Mild Steel

4 Heating Coil 1 Cu

5 Insulation Materials - Glass Wool

6 Copper Tubes 15 Feet Cu

7 Gate Valve 1 Mild Steel

8 Condenser Tank 1 Mild Steel

9 Waste Plastic 10Kg UPVC

10 Bolt and Nuts 20 M.S

25
11.2.LABOUR COST
LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =

11.3.OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

Overhead Charges = 20% of the manufacturing cost

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

Total cost for this project =

26
CHAPTER 12

RESULTS

27
 CHAPTER 13

CONCLUSION

13.1. SUMMARY

A strong multidiscipline team with a good engineering base is necessary for the

Development and refinement of advanced computer programming, editing techniques,

diagnostic Software, algorithms for the dynamic exchange of informational different

levels of hierarchy. Simulation techniques are suitable for solving some of the problems.

We gained a lot of practical knowledge regarding, planning, purchasing,

assembling and machining while doing this project work.

We are proud that we have completed the work with the limited time successfully.

The “FABRICATION OF EXTRACTION OF BIO-DIESEL FROM PLASTIC

WASTE MATERIAL” is working with satisfactory conditions. We are able to

understand the difficulties in maintaining the tolerances and also quality.

We have done to our ability and skill making maximum use of available facilities.

Thus we have developed an “EXTRACTION OF BIO-DIESEL FROM PLASTIC

WASTE MATERIAL” which helps to know how to achieve extraction of bio fuel from

plastics. By using more techniques, they can be modified and developed according to the

applications.

28
 REFERENCE

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1 diesel fuel: A recent reviewon diesel engine performance, emissions, and combustion
] characteristics," Science of the Total Environment , vol. 163756, 2023.

[ M. S. KR, R. K. N, P. J. Gogoi and R. P. S. Yadav, "Extraction of Bio-Diesel From Waste Plastic

2 Through Pyrolysis Process," International Journal of Engineering Research & Technology,
] 2022.

[ G. K, H. H. S, M. T. H, A. S and D. S. S, "Bio Diesel Extraction from Waste Plastic Material,"

3 Institute of Scholars.
]

[ M. Karlsson, L. Benedini, C. Jensen, A. Kamp, U. Henriksen and T. Thomsen, "Climate

4 footprint assessment of plastic waste pyrolysis and impacts on the Danish waste
] management system," Journal of Environmental Management, vol. 351, 2024.

[ W. Cai, R. Kumar, Y. Zheng, Z. Zhu, J. W. Wong and J. Zhao, "Exploring the potential of clay
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] Heliyon, vol. 9, 2023.

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