EPF

Zadgaonkars
Eco-friendly Plastic Fuel

Conversion of Waste Plastics

into
Liquid Hydrocarbons / Energy
Prof. Mrs. Alka Zadgaonkar
Head of the Department
Applied Chemistry
G. H. Raisoni College of Engineering
Nagpur.
 Plastics
What are Plastics?
Long Chain of molecules mainly composed of
Carbon and Hydrogen.

Plastics have occupied every spectrum of our

life
Light weight
Non Corrosive
Easily moldable
Ease of Manufacture
Economical
Non Bio-degradable
 Degradability of Different
Materials
Type of litter Degeneration Time

Organic waste etc. 1 - 2 weeks

Paper 1 - 3 Weeks
Cotton Cloth 8 - 20 Weeks
Wood 10 15 years
Wooden Items 10 Years
Tin, aluminium, and other 100 - 500 years
metals
Plastics A MILLION
YEARS ?
 Conventional Waste Plastic
Disposal
Landfills
Plastics are buried in the earth
It results in Toxicity of soil

Incinerators
Release of highly toxic gasses, if not done scientifically

Recycling
The Output product degrades after each cycle
Waste ultimately ends up in the Land fill
 Composition of MSW

Plastics
10%
Metals
Paper
2% Timber
Total 6%
compostables 6%
39% Glass
1%

Ash and fine Rags

Earth 3%
33%
Plastic Waste: Indian Scenario
2004-2005
10000 MT per day
36,50,000 MT per year
Advent of Disposable Culture
Plastic wastes generated in Industries and
imported plastic wastes are not included in
above data
Average 5-6% growth every year
 The Burning Facts
The Waste Plastic Disposal if addressed lightly

Improper Incineration is a major threat to ozone

layer. This loss is unquantifiable

Our future generations will blame us for the

situation that will exist then

The cost of these ecological disturbances is

unquantifiable
 Chronicle of the Invention
1991-92
Trigger thought
The Basic Principle: Random Depolymerisation
Selective Breaking of C- C Bonds
Fundamental Similarity in the structure of Plastic and
Fuel

1995 to 1999
Rigorous Research and Development
 H H H H
C C C C
H H H
n n
Polyethylene Polystyrene

H H H H
C C C C
H Cl H CH3
n n
Polyvinyl Chloride Polypropylene
 Invented Catalytic Additives
AZ1
AZ2
AZ3
AZ4
AZSP
 Liquid
Hydrocarbon,
Gas & coke

Reactor

De-
De- Gasification

Melting

Feed

Waste Plastic
 Input - Output
Input for the process is waste plastic and catalytic
additives

Output from 1Kg.of Waste Plastic

Product

Liquid Hydrocarbons 550 ml. to 600 ml.

Coke 125gms to 175gms
Gas Equivalent to produce net
2.25units of electricity.
The Quality of Liquid Distillate matches with Very High
Quality de-suphurised Crude
 Chronicle
2003
Invited for Demonstration at Indian Oil
Corporation (R&D Centre), Faridabad in front

Demonstration was also given at New Delhi

and Mumbai
Validation of process and products at Indian
Oil Corporation
Certification
Declaration of Grant for commercial plant by
Government
 Chronicle
2004
The declared grant was not received
Approached the biggest banker of India:
The State Bank of India
Technical as well as financial teams of SBI
thoroughly scrutinized the process
Loan was sanctioned
Erection work for Commercial 5 MT per day
capacity plant started in September
 Chronicle
2005
February 2005

Parameters were fixed

Decision to enhance capacity

Signed MoU with Government of Maharashtra

The work of Capacity Enhancement

from 5MT to 25MT is in progress
 Salient Features
The process is 100% Eco Friendly.
This process is not only a solution to the
waste plastic problem but can change global
economic scenario by saving millions of
dollars in import of crude oil.
This is a unique process through which 100%
waste is converted into value added products.
Percentage composition of output can be
altered by changing/adjusting reaction
conditions.
Liquid fuel obtained from first stage can be
directly utilized for D. G. Sets

From gas produced in the process, Electricity can

be generated
 How the process is Eco-Friendly?

Getting rid of plastic waste

Nothing is emitted in the atmosphere

No liquid effluents

Sulphur content in the fuel generated

is less than 0.002ppm
Details of Testing Equipment M/s. AVL India Pvt. Ltd..
Address of the Equipment Manufacturer Community Shopping Center,
Sector C, Pocket 9,
Vasant Kunj,
New Delhi 110070.
Details of fuel burning equipment Two Wheeler.
Name of the Manufacturer M/s. Hero Honda Motors.
Model Passion
Engine Capacity 100 cc, Four Stroke
Registration No. MH 31 BA 7277
Date of Testing 1st August 2005
Place of Testing / Testing on the request Unique Waste Plastic Management
of.. & Research Co. Pvt. Ltd.,
K-13, Butibori MIDC Industrial Estate,
Wardha Road, Nagpur

Emission Report
Name of Fuel used for Particulars Idling Acceleratio Acceleratio
testing n (Low) n (High)
Regular Petrol CO (%) 0.33 1.47 2.79
HC (ppm) 260 690 900
Process* out put as Fuel CO (%) 0.31 0.58 4.31
HC (ppm) 272 760 1010
Distilled Process* output CO (%) 0.27 0.61 3.57
as fuel
HC (ppm) 157 812 1100
Details of Testing Equipment M/s. AVL India Pvt. Ltd..
Address of the Equipment Manufacturer Community Shopping Center,
Sector C, Pocket 9,
Vasant Kunj,
New Delhi 110070.
Details of fuel burning equipment Diesel Generator Set
Name of the Manufacturer M/s. Kirloskar Oil Engine Limited
Model Engine - 6R1080TA, 125 kVA
Engine Capacity 156 bhp, 1500 rpm, water cooled
Registration No. -
Date of Testing 1st August 2005
Place of Testing / Testing on the request Unique Waste Plastic Management
of.. & Research Co. Pvt. Ltd.,
K-13, Butibori MIDC Industrial Estate,
Wardha Road, Nagpur

Emission Report
Name of Fuel used for Particulars Idling Load (50%)
testing
Regular Diesel CO2 (%) 17.70 34.70
17.90 34.90
21.80 31.40
average 19.13 30.80
average 32.95
Process* out put as Fuel CO2 (%) 15.80 27.80
15.50 28.20
15.80 28.40
15.80 28.90
16.30 36.30
average 15.84 average 29.92
Details of Testing Equipment M/s. AVL India Pvt. Ltd..
Address of the Equipment Manufacturer Community Shopping Center,
Sector C, Pocket 9,
Vasant Kunj,
New Delhi 110070.
Details of fuel burning equipment Kerosene Stove
Name of the Manufacturer M/s. Nutan
Model Commercial
Engine Capacity -
Registration No. -
Test Method Emissions through Chimney
Date of Testing 1st August 2005
Place of Testing / Testing on the request Unique Waste Plastic Management
of.. & Research Co. Pvt. Ltd.,
K-13, Butibori MIDC Industrial Estate,
Wardha Road, Nagpur

Emission Report

Name of Fuel used for Particulars Idling

testing
Regular Kerosene CO (%) 0.11
CO2 (%) 0.0
HC (ppm) 352
Process* out put as Fuel CO (%) 0.07
CO2 (%) 0.0
HC (ppm) 252
 TEST REPORTS
Date - DG Load Hrs/run Diesel units Generation Generation Remarks
capacit Consumed
y
produced per hr per/Ltr

1-1 2007 250 90KW 4.30 100 720 160 7.3 The fuel was not
KVA filtered

3-1-2007 250 130K 3.30 140 768 219 5.5 Filtered fuel was used
KVA W

21-1-2007 250 148K 5.00 205 1392 278.4 6.07 Filtered fuel was used
KVA W

The Units production by using normal Diesel is 3 to 3.5 units /per

Liters.
After using the Hydrocarbon fuel from Waste Plastics no
changes has been observed in generator parameters
 Savings on Crude Oil
Crude Oil Consumption in India 115 MMTPA

Crude Imported 80% 92 MMTPA

Waste plastic generated in India 10,000.00 MT/day

(excluding almost equal amount of
imported Waste dumped in India) i.e. 3,650,000.00 MT/annum

100
Liquid Hydrocarbons obtained in the Kilo-litre/
% 3,650,000.00
invented process annum
W/V

Quantity of crude that can be Kilo-litre

10,950,000.00
replaced by the output of the /annum
Zadgaonkars Process (Assumption:
Only the Waste Plastic generated in Barrels/annu
i.e. 54,750,000.00
India is processed.) m

Average rate of crude oil 60 USD per Barrel

USD
Saving on Foreign Currency 3,285,000,000.00
i.e. 144,540,000,000.00 Indian
Rupees
 The Dismal Present
our own waste plastic generation &
plastic dumping by foreign countries

India and neighboring countries are used as

dumping ground.

We are blaming other Countries for dumping

waste plastic in Indian Subcontinent
Advent of an Optimistic Future
By use of our Invention

We use the Invention to convert waste plastic

which is generated in our country and dumped by
others into fuels / energy

We Encourage dumping of plastic waste and

electronic waste.
Thus This Invention brings into
reality a famous jargon:

Hitting Two Targets

in a Single Bullet
 Recent Developments
Signed MoC with M. P. Council of Science
and Technology for a Demonstration plant
of 5 MT/Day Capacity at Bhopal, MP.
Erection of 25 MT/ Day capacity plant is in
progress at Kota, Rajasthan.
Chairperson Maharashtra Pollution Control
Board reviewed the technology by experts
and expressed satisfaction and interest to
work jointly for eradication of waste
plastics problem.
 International
Publication
Invited by Global leader in
technical publication Wiley, UK;
to contribute a complete chapter
in
World Polymer Series :
Feedstock Recycling &
Pyrolysis of Waste Plastics

Published in May 2006

Special Report
 An Important Point
Non-Utilization of Non Conventional
Energy sources
= No harm done to Environment

Non-Utilization of Waste Plastics

= Unimaginable harm to Environment
Lets Contribute To Make
the World Better Place to
Live.
 Contact
Mr. Suresh Shah
Chairman
Unique Group
&
Asian Electronics Ltd