by Pyrolysis
By
Abellar, Rodgie John
Alfaras, Mhelvene
Borlan, Randolph
Cabuguason, Paul Lyndon
BSChE 4
September 2014
CHAPTER 1
absence of oxygen in a closed environment, with the resulting products of pyrolysis available for
use as a chemical feedstock. Hydrolysis decomposes plastic wastes through a series of chemical
reactions. These new processes will reduce the cost of monomers and the consumption of
petroleum.
Pyrolysis is a thermal process that heats and decomposes a substance in an environment
from which oxygen is excluded. It can be used as a thermal conversion technique for
hydrocarbon wastes, where the waste materials are cracked to produce hydrocarbon oils, gases,
and char. The process can be optimised to maximise production of any of these constituents by
altering parameters such as process temperature and reactant residence time, a high temperature
and high residence time promotes the production of gases; a high temperature and low residence
time results in increased yield of condensable products, and a low temperature and heating rate
leads to increased char production or to no chemical reactions taking place at all. The wide
variety of pyrolysis products indicates that the products may need to be separated and purified
before they can be used further; this can usually be achieved through the use of existing distillery
and refinery facilities.
SPECIFIC OBJECTIVES
It specifically aims;
1.) To produce liquid fuel from 100g of plastic bags
2.) To determine the volume, mass and density of the produced fuel from 100g of plastics
3.) To test the flammability of the fuel
Environment
Conversion of disposed plastic bag into fuel could reduce pollution in the surroundings
by eliminating these wastes in landfills or dump sites. Improper disposal of these wastes could be
prevented and therefore it would enhance the conservation of the environment.
Community
The community could use the fuel produced for cooking, burning, transportation and for
energy production. It would also provide them financial support by selling the fuel to other
consumers.
have an effect on the generalizability of the study and its findings. However, its findings, at least
some portion and extent of it may still hold true to other different types of plastics.
DEFINITION OF TERMS
Operational
Disposed Polyethylene Plastic- plastics that are disposed in the community
Reactor- a container for the pyrolysis of plastic
Polyethylene- a thermoplastic polymer consisting of long hydrocarbon chains that are bonded by
the monomer ethylene
Polypropylene- a thermoplastic polymer consisting of long hydrocarbon chains that are bonded
by the monomer propylene
Polystyrene- a thermoplastic polymer consisting of long hydrocarbon chains that are bonded by
the monomer styrene
Liquid Fuel- combustible organic compound that are in liquid phase
Conceptual
Pyrolysis- a thermochemical decomposition of organic material at elevated temperatures in the
absence of oxygen (or any halogen). It involves the simultaneous change
of chemical
Condensation- is the change of the physical state of matter from gas phase into liquid phase
Char- the solid material that remains after light gases (e.g. coal gas) and tar have been driven out
or released from a carbonaceous material during the initial pyrolysis.
Synthetic gas- a fuel gas mixture consisting primarily of hydrogen, carbon monoxide, and very
often some carbon dioxide
Thermofuel- liquid hydrocarbon
Energy- a property of objects, transferable among them via fundamental interactions, which can
be converted in form but not created or destroyed
Landfill- a place to dispose of refuse and other waste material by burying it and covering it over
with soil, especially as a method of filling in or extending usable land
Carbon Black- a fine carbon powder used as a pigment, made by burning hydrocarbons in
insufficient air
Gasoline- a transparent, petroleum-derived liquid that is used primarily as a fuel in internal
combustion engines. It consists mostly of organic compounds obtained by
the fractional distillation of petroleum, enhanced with a variety of
additives
Chapter 2
History
The development of plastics has evolved from the use of natural plastic materials
(e.g., chewing
gum, shellac)
to
the
use
of
chemically modified,
natural
materials
(e.g., rubber, nitrocellulose, collagen, galalite) and finally to completely synthetic molecules
(e.g., bakelite, epoxy, Polyvinyl chloride). Early plastics were bio-derived materials such as egg
and blood proteins, which are organic polymers. In 1600 BC, Mesoamericans used natural rubber
for balls, bands, and figurines. Treated cattle horns were used as windows for lanterns in
the Middle Ages. Materials that mimicked the properties of horns were developed by treating
milk-proteins (casein) with lye.
In the 1800s, as industrial chemistry developed during the Industrial Revolution, many
materials were reported. In the 1800s, the development of plastics accelerated with Charles
Goodyear's discovery of vulcanization to thermoset materials derived from natural rubber.
Parkesine is considered the first man-made plastic. The plastic material was patented
by Alexander Parkes, In Birmingham,UK in 1856. It was unveiled at the 1862 Great
International Exhibition in London. Parkesine won a bronze medal at the 1862 World's
fair in London. Parkesine was made from cellulose (the major component of plant cell walls)
treated with nitric acid as a solvent. The output of the process (commonly known as cellulose
nitrate or pyroxilin) could be dissolved in alcoholand hardened into a transparent and elastic
material that could be molded when heated. By incorporating pigments into the product, it could
be made to resemble ivory.
In the early 1900s, Bakelite, the first fully synthetic thermoset, was reported by Belgian
chemist Leo Baekeland.
After World War I, improvements in chemical technology led to an explosion in new
forms of plastics, with mass production beginning in the 1940s and 1950s (around World War
II). Among the earliest examples in the wave of new polymers were polystyrene (PS), first
produced by BASF in the 1930s, and polyvinyl chloride (PVC), first created in 1872 but
commercially produced in the late 1920s. In 1923, Durite Plastics Inc. was the first manufacturer
of
phenol-furfural
resins. In
1933,polyethylene was
discovered
by Imperial
Chemical
Extreme
pyrolysis,
which
leaves
mostly carbon as
the
residue,
is
example,
to
wood,
to
called carbonization.
The
process
is
used
heavily
in
carbon, methanol,
the chemical
industry,
for
and
chemicals
from
other
convert ethylene dichloride into vinyl chloride to make PVC, to produce coke from coal, to
convert biomass into syngas and biochar, to turn waste into safely disposable substances, and for
transforming
like gasoline.
These
specialized uses of pyrolysis may be called various names, such as dry distillation, destructive
distillation, or cracking. Pyrolysis is also used in the creation of nanoparticles, zirconia and
oxides utilizing an ultrasonic nozzle in a process called ultrasonic spray pyrolysis (USP).
Pyrolysis
also
plays
an
important
role
in
such
as baking, frying, grilling, and caramelizing. In addition, it is a tool of chemical analysis, for
example, in mass spectrometry and in carbon-14 dating. Indeed, many important chemical
substances, such as phosphorus and sulfuric acid, were first obtained by this process. Pyrolysis
has been assumed to take place during catagenesis, the conversion of buried organic
matter to fossil fuels. It is also the basis of pyrography. In their embalming process, the ancient
Egyptians used a mixture of substances, including methanol, which they obtained from the
pyrolysis of wood.
Prior Arts
Dr. P. V. Thorat, Ms. Sandhya Warulkar and Ms. Harsal Sathone Pyrolysis of waste
plastic to produce Liquid Hydrocarbons with the abstract: Thermofuel is a process that converts
waste plastics into valuable liquid hydrocarbon product that can be utilized as energy source for
many purposes such as diesel engines, generators, vehicles, etc. The gaseous by-product obtained
in the process can be used for domestic use by refilling it in the cylinders and also to run gas
turbines. Thus thermofuel process can be considered as another non-conventional energy source.
We all know that crude oil is the ultimate source of plastics and most of the chemicals. Out of
total 100 million tons plastics produced every year all over the world, 25 million tons is dumped.
By dumping such hefty amount of waste plastics, we are wasting lots of energy in the form of
crude oil that is used to make plastics. This wasted energy can be recovered back using
thermofuel process. By doing this we can save our conventional energy source i.e. crude oil and
ultimately country foreign exchange.
From Su Shiung Lam and Howard A. Chase, in their study A Review on Waste to
Energy Processes Using Microwave Pyrolysis
Abstract: The paper presents an extensive review of the scientific literature associated
with various microwave pyrolysis applications in waste to energy engineering. It was established
that microwave-heated pyrolysis processes offer a number of advantages over other processes
that use traditional thermal heat sources. In particular, microwave-heated processes show a
distinct advantage in providing rapid and energy-efficient heating compared to conventional
technologies, and thus facilitating increased production rates. It can also be established that the
pyrolysis process offers an exciting way to recover both the energetic and chemical value of the
waste materials by generating potentially useful pyrolysis products suitable for future reuse.
Furthermore, this review has revealed good performance of the microwave pyrolysis process
when compared to other more conventional methods of operation, indicating that it shows
exceptional promise as a means for energy recovery from waste materials. Nonetheless, it was
revealed that many important characteristics of the microwave pyrolysis process have yet to be
raised or fully investigated. In addition, limited information is available concerning the
characteristics of the microwave pyrolysis of waste materials. It was thus concluded that more
work is needed to extend existing understanding of these aspects in order to develop
improvements to the process to transform it into a commercially viable route to recover energy
from waste materials in an environmentally sustainable manner.
Nasrollah Hamidi, Fariba Tebyanian, Ruhullah Massoudi and Louis Whitesides in
Pyrolysis of Household Plastic Wastes with abstract: To design the experimental procedure, we
primarily concentrated on the thermal stability of the materials by bearing in mind the results of
thermogravimetric analysis (TGA). Based on the thermogravimetric results the appropriate setup for the decomposition of the plastic wastes was designed. Three common household plastic
wastes styrofoam dining plates (SDP), shipping protection styrofoam boxes (SPFB), and
carrying plastic shopping bags (CPB) were pyrolized into liquids. GC-MS was used to
characterize the sample of the obtained liquids.
According to Dr. P. V. Thorat, Ms. Sandhya Warulkar and Ms. Harsal Sathone in their
research entitled Pyrolysis of waste plastic to produce Liquid Hydrocarbons, the gaseous byproduct obtained in the process can be used for domestic use by refilling it in the cylinders and
also to run gas turbines. Thus thermofuel/ liquid hydrocarbon process can be considered as
another non-conventional energy source. Thermofuel is a truly sustainable waste solution,
diverting plastic waste from landfills, utilizing the embodied energy content of plastics and
producing a highly usable commodity that, due to its cleaner burning characteristics, is in itself
more environmentally friendly than conventional distillate. Su Shiung Lam and Howard A.
Chase, in their study A Review on Waste to Energy Processes Using Microwave Pyrolysis
states that the oil and gaseous products demonstrated a high calorific value, and the char
10
produced can be used as a substitute for carbon black. In particular, the gaseous product is of
considerable interest due to its potential as a source of hydrogen fuel.
Nasrollah Hamidi, Fariba Tebyanian, Ruhullah Massoudi and Louis Whitesides in Pyrolysis of
Household Plastic Wastes stated that the nature, yields, and the chemical compositions of the
liquids produced by pyrolysis of the waste plastics depended on the engineering of the process
and the kind of waste being used. Also, the liquids produced needed further refinements in order
to be suitable for use as fuel or fine chemicals. The compositions of the remaining materials at
the end of the process also depended on the kind of wastes that underwent pyrolysis. Liquid
resulting from pyrolysis of carrying plastic bags was a mixture of alkanes and alkenes up to 24
carbon chains. The hydrogenation of higher alkanes in this mixture produced long chains
hydrocarbons similar to synthetic lubricants. Also, the portion of C4 to C11 was suitable for the
production of light gasoline and the portion of C12 and higher was found to be suitable for diesel
fuel. Pyrolysis of foams produced a mixture of more than 350 chemicals. The most abundant
compounds were styrene, styrene derivatives and their isomers, vinyl compounds and other
highly reactive substances. This mixture was polymerized while it was stored in the dark for two
months at room temperature in the lab. Refinement of these materials resulted in styrene and its
derivatives that are valuable fine chemicals.
S.L. Low, M.A. Connor and G.H. Covey in Turning mixed plastic wastes into a useable
liquid fuel experimented that a simple batch pyrolysis method can convert polyolefins and
polystyrene to liquid hydrocarbon products with a yield of at least 70%. Preliminary tests using
mixed waste plastics were promising and confirmed the feasibility of converting such wastes to
liquid products. These liquid products have compositions overlapping those of major existing
hydrocarbon fuels such as petrol, diesel and kerosene. Use of these products directly as a fuel or
11
12
for reprocessing in a refinery therefore appears possible. The study performed in this paper has
provided important information showing that prospects for using small-scale simple pyrolysis
processes to deal with waste plastics appear good but further investigations are required.
Nagi Insura, Jude Onwudiliand Paul T. Williams in their Converting Waste plastic To Gasolinelike Fuel at low temperature showed that the gas product is dominated by propane and butane
gases compared to that in absence of catalyst. The derived oil structure changed to a light
structure where concentration of aliphatic fraction is decreased. Oil components distributed
within boiling point range up to 240 C. The main aromatic hydrocarbons in the oils were
toluene, ethylbenzene, xylenes, propylbenzene, butyl benzene, benzene in addition to short chain
aliphatics and cycloalkanes dominated by C6 and C7.
13
Chapter 3
METHODOLOGY
Samples Preparation
Disposed polyethylene plastic bags are randomly collected within the area around
Bacolod city. They are put together in a big plastic bag and weighed. The chosen plastic bags are
described as clean and dry.
14
Plastics
Can
Epoxy
Lighter
Electric stove
Weighing scale
Plastic bottle
Ruler
Tap water
Plastic tube
Procedure
The can is cleaned and punched. The reactor is then made by connecting the plastic and
metal tubes into the hole using an epoxy. Collected disposed plastic bags are weighed at about
100g and put into the reactor. The reactor is then closed and placed in the electric stove. The
plastic bottle is filled with tap water and its weight is measured. The reactor is heated for half an
hour to recover the liquid fuel and to complete the pyrolysis. The incondensable gas which is the
gaseous fuel is released in the atmosphere. The condensable gas produced in pyrolysis which is
the liquid fuel is collected in the plastic bottle container where water is present. The produced
fuel will eventually form at the top portion since fuel is less dense than water. The separate
products are cooled in a water bath. See figure 1.
15
incondensable
gases
polyethylene
plastic bags
condensable
gases
fuel
fuel
water
stov
e
Chapter 4
RESULTS AND DISCUSSION
Trial
wt.
bottle+
water
(g)
wt.
bottle+
water
+ fuel
(g)
wt.
fuel
(g)
circumference
of
bottle
(cm)
height
(cm)
volume
of fuel density
(cm3)
(g/cm3)
flammability
color
262
269
17
0.5
11.5
0.6087
yes
256
270
14
17
0.9
20.7
0.67633
yes
265
273
17
0.6
13.8
0.57971
yes
yellow
brown
yellow
= constant
17
14
12
10
8
6
4
2
trial 1
trial 2
trial 3
0
1
mas
s
(g)
Trial 2 produced the largest mass of fuel which is 14g while trial 3 has the smallest which is 7g.
25
20
trial 1
15
trial 2
trial 3
10
5
0
1
volum
e
(cm3)
The largest volume produced was at trial 2 which was 20.7 cm3 and the smallest was at trial 1
which was 11.5 cm3.
18
0.68
0.66
0.64
trial 1
0.62
trial 2
0.6
trial 3
0.58
0.56
0.54
0.52
1
The trial 2 has the largest density which was 0.67633 g/cm3 and the smallest was in trial 3 which
was 0.57971 g/cm3 .
Graph 1.4 shows the time vs. density of fuel at different trials
0.7000
0.6000
0.5000
0.4000
trial 1
0.3000
trial 3
trial 2
average
0.2000
0.1000
0.0000
0
10
20
30
Densit
y
(g/cm3
)
time (min)
Graph 1.5 shows the enlarge view of different density produced at different trials
19
0.7000
trial 1
trial 2
0.6000
trial 3
average
0.5000
25
For half an hour of pyrolysis, the 2nd trial has recovered the largest amount of fuel while
volume
(cm3)
Another factor was the components present in the fuel. The gas produced during pyrolysis may
take different substances like gasoline, kerosene, and diesel. These substances have different
properties like the density and solubility in the water which could contribute to the discrepancy
in the measured variables. The other factor was the weighing balance used. The equipment
showed irregularities in the value even at repeated trials. This could contribute to the error in the
measurement.
The maximum amount of fuel was recovered at trial 2 because the problems encountered
at trial 1 were somehow anticipated though there were still problems that were beyond the
control of the researchers. The gas produced during pyrolysis was at high temperature. The
condensation of this high temperature gas was done when it would physically come into contact
with the water in the bottle container producing small bubbles around the area. Bubbles are
formed at the late 5 minutes taking much pressure to displace the water in the container. On the
other hand, the incondensable gas was released in the atmosphere. The recovered fuel was then
observed by its color to compare it to the commercial fuels available in the market. Three trials
take slight difference in appearance which the trial 2 has brownish shade compare to the trial 1
and trial 3 which has yellowish shade. Then the fuel produced was undergone to flame test. A
small sample was taken and it was ignited using a lighter. The fuel burned and produced a
smoke. The test finally revealed that the product was combustible fuel.
20
21
Chapter 5
CONCLUSION AND RECOMMENDATION
The polyethylene plastic bags produced liquid fuel by pyrolysis. In the pyrolysis process,
there was no oxygen present and the temperature was above 200 oC. There were of two types of
gases formed, the condensable and the incondensable gases. The condensable gases undergone
phase change forming the liquid fuel. The condensation occurs when the gas come in contact
with the cooling medium which is the water. The pressure exerted by the gas would create
bubbles as a result of displacement. The less dense fuel would be suspended at the top of the
water forming a layer. Char was produced after the pyrolysis process . The char residue produced
is generally proportional to the level of contaminants. A 100g polyethylene plastic bag could
produce an average of 9.67g of liquid fuel with a volume of 15.33 cm3 and a density of
0.63079g/cm3 in half an hour operation. The largest yield was 14% and the lowest was 7% by
weight. The color of the fuel was yellow to brown. It was combustible when tested producing
smoke at normal condition. The recovery of fuel was increased when there was no leakage in the
set up. The study performed in this paper has provided important information showing that
prospects for using small-scale simple pyrolysis processes to deal with disposed plastics appear
good but further investigations are required.
Liquid fuel is a truly sustainable waste solution, diverting disposed polyethylene plastic
bags from landfills, utilizing the embodied energy content of plastics and producing a highly
usable commodity that, due to its cleaner burning characteristics, is in itself more
environmentally friendly.
22
BIBLIOGRAPHY
S.L. Low, M.A. Connor and G.H. Covey. (2001). Turning mixed plastic wastes into a useable
liquid fuel, Department of Chemical Engineering University of MelbourneMelbourne,
Victoria 3010 Australia.
Nasrollah Hamidi, Fariba Tebyanian, Ruhullah Massoudi and Louis Whitesides. (2013).
Pyrolysis of Household Plastic Wastes. Department of Biological and Physical Sciences,
South Carolina State University, Orangeburg, SC 29117, USA.
M. S. Mulgaonkar, C. H. Kuo, A. R. Tarrer. (1993). Plastics Pyrolysis Coal Coprocessing with
Waste Plastics. Chemical Engg Dept Auburn University Auburn. Al-36849
Dr. P.V. Thorat, Miss. Sandhya Warulkar ,Miss.Harshal Sathone. (2013). Thermofuel
Pyrolysis of waste plastic to produce Liquid Hydroocarbons. Department of Polymer
Technology, College of engineering and technology Akola, NH6, Murtizapur Road,
Babhulgoan (JH),Akola-444104 ,Maharashtra State INDIA.
Su Shiung Lam and Howard A. Chase. (2012). A Review on Waste to Energy Processes Using
Microwave Pyrolysis. Department of Engineering Science, Faculty of Science and
Technology, Universiti Malaysia Terengganu, 21030 Kuala Terengganu, Terengganu,
Malaysia.
Nagi Insura, Jude Onwudili and Paul T. Williams. (2009). Converting Waste plastic To
Gasoline-like Fuel at low temperature. Energy and Resource Research Institute, School of
Process, Materials, Environmental Engineering, University of Leeds.
Shah, J.K., T.J. Schultz, and V.R. Daiga, 1989. "Pyrolysis Processes." Section 8.7 in Standard
Handbook of Hazardous Waste Treatment and Disposal, ed. H.M. Freeman. McGraw-Hill
Book Company, New York, NY.
J.A. Gonzlez-Prez, G. Almendros, J.M. de la Rosa, F.J. Gonzlez-Vila. (September 2014)
23
APPENDIX I
Preparation of Materials
The reactor
24
APPENDIX II
Trial 1
Trial 2
Trial 3
25
APPENDIX III
Liquid Fuel in
Trial 3
Liquid
26
APPENDIX IV
Flame Test
Char
Table of Contents
Chapter 1
Background of the Study......................1
Statement of the Problem..2
Specific Objectives3
Significance of the Study...3
Scope and Limitations....3
Definition of Terms4
Chapter 2
Review of Related Literature.6
Chapter 3
Methodology..13
Samples Preparation...13
Materials and Equipment...14
Procedure...14
Chapter 4
Results and Discussion..16
Chapter 5
Conclusion and Recommendation.21
Bibliography..22
Appendix I IV.26