🏭 Case Studies from Operational Plastic to Fuel Plants

 

Case Studies from Operational Plastic to Fuel Plants

1. India – Small-Scale Modular Pyrolysis Plant (5 TPD)

Location: Gujarat, India
Operator: GreenEnvy Tech Pvt. Ltd.
Feedstock: Mixed post-consumer plastics (LDPE, HDPE, PP)

Key Features:

  • Modular skid-mounted design for rural deployment

  • Operates at 450–500°C under vacuum

  • Uses ceramic wool insulation and indirect heating via thermic oil

Performance:

  • Yield: 60–65% fuel oil, 20% gas, 10% char

  • Output used for internal diesel generator

  • Fully automated with PLC controls and gas recycling loop

Challenges:

  • Impurities in mixed waste required pre-washing unit

  • Catalyst fouling reduced yield after 4 months (solved by switching to alumino-silicate)


2. USA – Industrial Scale Plant (25 TPD)

Location: Ohio, USA
Operator: RES Polyflow (now Brightmark Energy)
Feedstock: LDPE films, mixed packaging waste, low-grade post-MRF residue

Key Features:

  • Horizontal rotary kiln pyrolysis

  • Operates in batch-mode with 8-hour cycles

  • Uses synthetic zeolite catalyst

  • Designed with integrated emission treatment (scrubber + activated carbon)

Performance:

  • Oil Yield: ~68%

  • 100% of non-condensable gases reused for heating

  • End product certified as off-road diesel (ASTM D975-compliant)

Lessons Learned:

  • Proper size reduction critical for uniform heat transfer

  • Gas cleaning system needs daily maintenance for optimal VOC removal


3. Japan – Compact Urban Plant (10 TPD)

Location: Osaka, Japan
Operator: Blest Co. Ltd.
Feedstock: Clean HDPE & PP industrial waste

Key Features:

  • Compact design for urban siting

  • Fully enclosed system with odor control

  • Fast startup time: <2 hours

Outputs:

  • Fuel: Paraffinic oil used in small engines

  • Offgas: Compressed and bottled for use as backup fuel

  • Char: Sold as filler for asphalt products

Innovations:

  • Real-time process analytics (IR sensors)

  • CO₂-neutral cycle by integrating solar-powered heating


4. Kenya – Community-Based Plant (2 TPD)

Location: Kisumu, Kenya
Operator: EcoFuel Africa
Feedstock: Agricultural plastic waste and bags

Key Features:

  • Locally fabricated fixed-bed reactor

  • Manual loading and gravity discharge

  • Operated by women cooperatives as income generation

Products:

  • Oil used for powering irrigation pumps

  • Gas flared due to lack of storage system

  • Ash used in brick making

Social Impact:

  • Created 25+ jobs

  • Reduced open burning of plastic

  • Enabled clean water access through pump deployment


5. China – Co-Processing in Cement Kilns

Location: Shandong, China
Operator: SINOMA Cement Plant
Feedstock: Shredded mixed plastics (<50 mm)

Key Features:

  • No separate pyrolysis unit: plastics co-processed in cement kiln at >900°C

  • Energy recovered directly in clinker production

  • No fuel oil produced, but fossil fuel savings achieved

Benefits:

  • Replaces up to 10% coal input

  • No additional emissions (confirmed via stack testing)

  • Integrated into waste management plan of city


📊 Comparative Summary Table

Case

Capacity

Feedstock

Yield (Oil)

Energy Use

Tech Highlights

India

5 TPD

Mixed plastics

60–65%

Thermic oil

Modular, off-grid ready

USA

25 TPD

MRF residue

~68%

Gas reuse

ASTM-grade diesel

Japan

10 TPD

Clean HDPE/PP

70%

Low

Urban setup, odor control

Kenya

2 TPD

Agri waste

55%

Biomass

Community-led design

China

20–50 TPD

Shredded mix

N/A

Kiln-integrated

Co-processing, no residue


📝 Key Takeaways

  • Feedstock quality significantly influences oil yield and process stability.

  • Catalyst selection and pre-treatment are critical to long-term performance.

  • Automation and safety systems are vital, even at small scales.

  • Plants that integrate energy recycling and environmental controls achieve the best sustainability profiles.

  • Social impact and economic viability are major drivers in developing countries.

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