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Plastic to oil using catalytic pyrolsis

Plant location: - Davengere, Karnataka.


Plant Capacity: - 2 Ton/ Batch.
Plant type: - Semi batch process
Equipments:-
1) Air blower and heater
2) Reactor
3) Condenser
4) Scrubber
5) Pretreatment equipments
6) Collection & Storage tanks.
7) Oil pumping pumps
8) Cyclone precipitator
Raw materials:- Polyethylene/Poly, CPP, PE, PET, PT, HDPE, LDPE
Product :- 20% Gas (C
2
H
4
, CH
3
, Co
2
)
70% oil Mixture C
n
H
cn
, C
2
, H
2

10% (Carbon Solid)
Caloric value 11,000/-

Mass Balance
Feed: 20 Kg per feed / Mixture of plastic
Overall reaction :- Input out put
(20 Kg Plastic mixture Catalysis (oil(70%) +(20%) gas + (10%)solid )
300c to 350c
(20 Kg Plaster 14 liter Gil, 4 liter gas 2 kg carbon powder.)
To convert 20 Kg plastic oil 0.3% catalyst is required.
20Kg Plastic + 0.3% catalyst is feed.
20 Kg plastic + 0.6Kg catalyst


14.liter - oil 4 litter Gas + 2 Kg Carbon solid
Per day: - 8 hrs operation
Total input :-150 Kg / Hr/batch X8X 70% oil.
Per day: - 840 Liter oil can be produced from 1200 Kg
1200 Kg plastic/ day 120 kg Carbon solids
240 liter Gas.
Energy balance
To heat 300
0
C to 350
0
c energy required (intension of oil)
12 to 15 liter Diesel per batch to pimp oil and strange 20 energy resumption
Percent plant energy consumption

Input


Recylc


30% of produce oil from plastic using for reactor + heating + pump
20% gas produced is also using for reactor + heating
25 HP (electricity )pumps are using to run the pump


Classification of plant operation
1) Ideal condition energy input
2) Altered energy input
Air
blower
and
heater
Reactor
Cyclone
precipitato
r
Condens
er
Ideal condition Altered condition
Petroleum diesel used as energy
source
Oil produced from plastic used as
energy source (recycle )
Ball pumps Gas (20%)also used as energy source
Residence time 10 mins /20 kg 150kg/ hr


Economics: (present Condition in plant)
Working Capital
Raw materials :- 20 kg (Plastic mixture)
Per Kg 8Rs including Trasport
20Kg X 8= 160 Rs
Catalyst Cost:-Per Kg -22 Rs
0.6X22=13.2 Rs
Energy cost for 2 Tons batch process
I deal condition energy in put Alternate Condition input
Per batch = 15 liter Diesel / Batch 30% -4.2 liter
20% Gas input
Total=1035 to 1500 Rs /batch Total= 600 Rs to 1000 Rs /ba


Total materials Cost Balance
2 Tons= 150 Kg input
1200 Rs Plastics
132 Rs Catalysiss
1500 Rs Ideal energy in put /batch
2838 Rs = Total Cost/batch

Per day
150X8 hrs X8 Rs Plastics
9600 Rs = Plastic /Day
132 X 8 hrs = catalysis
1056 = Catalysis cost /day
1500 X 8 = 12,000 energy / day

25 HP liter energy input pumping cost
25 HP = 1000 Rs Per day Converted to waits X kj X 1000 Rs
Labor:- 5 to 8 8X1000
8000 Labor
Miscellaneous:- 1000 to 2000 Rs (Transport+office))

Per day Total Cost
9,600 Plastic raw
1,056 catalysts
12,000 energy input
1,000 25 Hp Pumps
8,000 Labor
2,000 Miscellaneous
33,656 Total
840 liters = Cost = 45 Rs X 840 Liters=37800/ sale /day

37800 4000 + Rent
33400
4000 Loss amount




Present condition with ideal energy
input is loss with 4000.
Altered energy input Economic
9600 - Plastic
1050 - Catalyst
8000 - Energy
1000 - Pump energy + stored
3000 - workers
2000 - Miscellaneous
3000 - Rent & Transport
27650
37500-----overall income
27650 ----expenditure
09850 Profit .
Till not able to manage because premising problem.
Like 1) choking
2) Abstraction
3) Pumping

Present Problem:-











Raw materials, choking and energy
input.
Forecasted balance sheet if we buy.
Plant location :- Bangalore or Tumkur.
Total plant cost :- 40 Lakhs
Per share = 4 lakhs X 10 persons share = 40 lakhs
3Rs/ Kg Raw materials in Bangalore
150 X 8 X 3 = 3600
3600 - Plastic
1050 - Catalyst
8000 - Energy
1000 - Pump energy + stored
3000 - Workers
2000 - Miscellaneous
3000 - Rent & Transport
21650 total expenditure
37500 Rs. Total incomes from oil
21650 Rs. Total expenditure

15,850 1day profit
15,850 X 26 days = 4,12,100 Rs Profit/Month
4, 12,100/10 persons share =41,210 Rs /month
41,210/ per share / per month
41210 X12 months =494000 profit each year( amazing )
494250 per year
One time Investment 4,00,000/-
Each year 4, 94,000 Rs profit

Deprecation / company growth amount not included.

Cheers