Retrieving Plastic Waste Material and Automatic Continuous Feed Pyrolysis Fuel Plant

INTRODUCTION:

This process is divided into two parts, namely the pre-screening waste plastics automatic recycle plant and the automatic continuous feeding pyrolysis renewable fuel plant.

Pre-Screening Equipment Plant

1. This plant is installed in landfills and will automatically select and recover the plastic waste. The process is as follows: the plastic waste is transported daily to the automatic pre-screening plant. After shredding the plastic bags, vibrate screening, vacuuming, magnetic selection, waste plastic extrusion are then sent to the pyrolysis plant.

The waste plastic pre-screening recycle plant will for each 1,000 tons of fresh garbage recycle 100 tons of waste plastic material - the recovery rate is about 10%. Installing this plant can reduce mountains of landfill sites around the world.  This pre-screening recycle plant can also apply to recycle waste plastic bags.

Pre-screening process is as follows:

a.) Retrieving Plastic Waste Material from landfills

b.) After pre-screening by the automatic plant, recycled plastic waste is sorted.

c.) The plastic waste is automatically packed and transported to the pyrolysis plant.

2. WT Type – Waste Plastic Automatic Continuous Pyrolysis Fuel Plant
This plant needs to be installed in an industrial zone and meets all the advanced countries’ environmental protection emission standards. The pre-screening waste plastic is converted by pyrolysis process and conversion rate is about 70 percent (cracking and refining the burning oil, unleaded petrol, diesel and other products).

WT Type –the process is as follows:

a.) Waste plastic continuously fed into the pyrolysis plant.

b.) Waste plastic is continuously cracked and is controlled by the pyrolysis console.

c.) The waste plastic becomes liquefied.

d.) The liquefied waste plastic is processed and fed continuously into pyrolysis plant.

WT Type - the equipment

Technology and the procedure

According to waste polymeric material research one is required to design the equipment in order to convert and reduce the plastic waste product into fuel.

The plant has ten major processes:

• Plastic waste breaking process.
• Preheating Raw materials process.
• HCL-absorbing process.
• High temperature burning heating process.
• Solid alloy thermal ball heating process.
• Automatic continuously feeding catalytic cracking process.
• Smoke Purification process.
• Heat exchanger cooling process.
• Fractionation refining process.
• Sludge - Harmless brick processing system.
• This equipment has a very low requirement for maintenance - no cleaning or sorting, and uses an automatic conveyor feeding system - while one side feeds the raw plastic, the other side is supplying oil and de-slagging.

All plastics are composed from crude oil - Carbon (C) and Hydrogen (H). Petroleum is composed of two components: hydrocarbons and the other non-hydrocarbons - Oxygen (O), Sulfur (S) and Nitrogen (N). The composition of petroleum hydrocarbons, the chemical polymer, namely, Carbon and Hydrogen is the major component of plastic - plastic is produced from petroleum. Waste Plastic under pressure and catalytic cracking produces fuel and can be used as a fuel source. Under certain temperature conditions the plastic macromolecular chains are converted to small molecular chains (which is a hydrocarbon compound) and those small molecular compounds contain C4 ~ C20, this compound is a component of petrol, coal oil, and diesel. Under this catalytic pyrolysis process the wax oil and heavy oil are removed.

WT Type -Pyrolysis Process

The shredded plastic waste is automatically and continuously fed into the pre-heating process; the plastic waste melts at this stage, PVC as it has a low melting point will crack first and the HCL will be removed in this process.

After preheating, the melted plastic is fed into the continuous cracking furnace. The cracking furnace has a solid mesh and is cyclically heated to ensure the waste plastic is completely converted by the pyrolysis reaction. Any residues are removed automatically from the cracking furnace to ensure nontoxic operation.

The pyrolysis gas fractionation and subsequent cooling from the fractionation tower, produces light and heavy oil fractions and a small amount of non-condensable gas. The light oil fraction (light gasoline) is separated and the heavy oil fraction is fed into the re-boiler and re-processed by secondary catalytic cracking. This process produces a high-quality automotive diesel. The non-condensable gas from this purification system is used as the fuel to heat the pyrolysis system and the whole process is self-sufficient. The process by the purification system achieves all developed countries’ emissions standards.

WT Type equipment technique:

The plant uses rotary drum catalytic pyrolysis technology - the shredded recycled waste plastics is fed continuously into the cracking furnace to increase thermal efficiency and maximize processing power.

In the preheating stage, the pyrolysis plant process purifies the mixed waste plastic PVC material and harmful gases such as HCL gas are removed, this in turn protects the equipment from erosion. Inside the Pyrolysis plant the gas is fed into catalytic converter then cracked, fractionation, cooled and separated. The non-condensable gas is purified and supply for the heating process and production use, the generated flue gas purify again by the flue gas purification system to meet the developed countries’ emission standard.
The cracking pyrolysis system produces carbide and is fed onto a conveyor system to the combustion furnace for combustion and removal. The generated harmless ash is automatically collected and is environmentally cured.

Waste Plastic Pyrolysis Production line equipment:

Feed waste plastic 15 Tons/day , maximum 500 kW / hour  electricity consumption, 15 labor ( 3 shifts for 24 hours )
Output 8 Kilo litre /day ( 75% Diesel, 20% Petrol , 5% fuel )

• Breaking System
• Raw material Preheating System
• Heating System
• Pyrolysis System
• Catalytic Cracking System
• Cooling System
• Gas Purify System
• Smoke Purify System
• HCL Removal System
• Dual Electrical Control and Monitoring System