Mixed Waste Plastics to Diesel

Process

Step 1 - Solid to Molten

Plastic Pellets are loaded into the Injection Machines where it will be heated and becomes molten.

Step 2 - Molten to Gas

The Molten Plastics will be injected into the Reactor where it will gasify and cracked.

Step 3 - Gas to Liquid

The gas will flow to a Distillation Column where it will condense and be changes the gaseous state back into a liquid.

Process description of the SYNGAS CONVERSION PLANT

Process Steps

Conversion Process Diagram
The Raw Materials and types of plastic
Shredding the Raw Material
Palletizing the Raw Material
Palletized Raw Material
Feedstock ready for Extrusion Machine
Feedstock ready for the hopper
Extrusion Machine Heaters and material rate flow set
Reactor Heater Temp Set
Agitator of Reactor turned on
Molten plastic extrusion processes
Start up process required for continuous running
Condensed Gas Cooling
Clear Diesel Oil Output
Syngas Diesel Tested in Generator

This operation constitutes a new process which has several advantages compared to conventional processes for energetic usage of waste material and thermal treatment of residues.

The process operates at temperatures of 340-410°C transforming mineral waste oil to fuel or diesel oil.

Input (Mineral Waste Oil and Plastics) is filtered and preheated by steps to 250° C. All water enclosed in the input is eliminated. Discharge gases are expelled into an exhaust filter. The oil is then injected into the heated reactor chamber. Waste heat of the reactor chamber is used for preheating.

Reactor chamber is completely separated from the distillation equipment.

Transformed residual substances in gaseous state are guided through a high speed cyclone into a pressure secure container. There the vapours are cleaned from aerosols and particles carried along. Special tubing permits transfer from the security chamber to the distillation unit.

As the operational temperature of 390°C is reached steaming hydrocarbons are fractured and transmitted to the distillation column and converted back via condensation to liquid fuel.

With this process and such a low temperature there is hardly any decomposition into coke crystals which creates a black tarry deposit; this deposit must be removed from the surface of the reactor chamber. A rotating scrubber continuously removes the residue without spark emission. It also optimizes heat transfer to the input material. Residual tar material is used for road building.

Using a steady temperature control in this process guarantees an extremely low volume of gas (4.5% instead of the usual 40%). The gas itself is used to heat the reactor chamber to process temperature.

The key elements and advantages of this process, therefore, are as follows:

  • Low volume smoke gas
  • No residue resin or partially burned gases
  • Low process temperature
  • Self cleaning reactor chamber guaranteeing excellent heat transfer
  • Separation of reactor chamber and distillation for high ignition security
  • Connection between both elements through a foam brake.
  • Very clean end product
  • No pyrolytic hydrocarbons and gaseous mixtures creating application problems

These elements result in a final product of high quality synthetic lightweight oil. More than 90% of the input material is transformed into fuel or diesel oil.