๐Ÿ› ๏ธ Technical & Engineering Feasibility Study for 10 TPD Plastic to Fuel Plant

 

This feasibility study evaluates the technical and engineering viability of constructing and operating a plastic-to-fuel (PTF) pyrolysis plant with a daily processing capacity of 10 metric tons (TPD) of mixed plastic waste.

 ๐Ÿ“Œ 1. Project Overview

This feasibility study evaluates the technical and engineering viability of constructing and operating a plastic-to-fuel (PTF) pyrolysis plant with a daily processing capacity of 10 metric tons (TPD) of mixed plastic waste. The plant converts non-recyclable plastics into liquid fuel, non-condensable gases, and solid char using a controlled thermal pyrolysis process.


๐Ÿงช 2. Applicable Science and Engineering Principles

  • Thermal Decomposition:
    Pyrolysis is governed by thermochemical decomposition of polymers at 300โ€“500ยฐC in an oxygen-free environment, breaking long-chain hydrocarbons into smaller molecules.
  • Heat Transfer Mechanism:
    Critical to the process is efficient conduction and convection heat transfer within the reactor walls and feedstock bed.
  • Reaction Kinetics:
    First-order kinetics dominates for HDPE and LDPE, with rate constants influenced by temperature, pressure, and catalyst selection.
  • Catalysis (Optional):
    Use of zeolites (e.g., ZSM-5) or alumina/silica-based catalysts can enhance oil quality and reduce gas yield.

๐Ÿ—๏ธ 3. Main Components and Process Units

  1. Feedstock Preparation Unit:
    • Shredders and dryers for plastic conditioning (size < 20 mm).
    • Magnetic and density separators to remove metals and debris.
  2. Pyrolysis Reactor (Batch or Semi-Continuous):
    • Material: SS316/310S for corrosion and heat resistance.
    • Heating: External furnace (diesel/gas/electric).
    • Operating temp: 350โ€“450ยฐC.
    • Pressure: Slightly above atmospheric (~1โ€“1.2 bar).
  3. Condensation System:
    • Series of shell-and-tube or air-cooled condensers.
    • Oil tank for liquid fuel collection.
    • Demister for tar removal.
  4. Gas Handling Unit:
    • Non-condensable gases redirected to burner for process heat.
    • Scrubber with NaOH/activated carbon for emission control.
  5. Char Removal & Handling:
    • Manual or screw discharge.
    • Bagging for sale/use as fuel or filler.
  6. Control & Instrumentation:
    • PLC/SCADA with I/O for temperature, pressure, level, gas detection.
    • Emergency shut-down interlocks.

๐Ÿงฑ 4. Material of Construction (MoC)

Component

Recommended MoC

Standards

Reactor Shell

SS310 / Inconel

ASME Sec VIII

Condensers

SS304 / CS with FRP

API 660

Feedstock Conveyors

Mild Steel (Painted)

IS 2062

Piping

CS/SS

ASTM A106/A312

Control Panels

IP55 Enclosure

IEC 60529


๐Ÿงพ 5. Process Inputs & Outputs

Stream

Input/Output

Quantity (Daily)

Plastic Waste

Input

10,000 kg

Liquid Fuel

Output

~6,000โ€“6,500 L

Non-condensable Gas

Output

~1,500โ€“2,000 mยณ

Solid Char

Output

~1,000โ€“1,200 kg


๐Ÿ›ก๏ธ 6. Safety and Environmental Systems

  • Fire & Gas Detection: LEL detectors, flameproof junction boxes, foam extinguishers.
  • Pressure Relief System: Rupture discs and spring-loaded relief valves.
  • Gas Scrubber: Caustic scrubber to neutralize acidic gases (HCl, SOx).
  • Effluent Handling: Zero-liquid discharge (ZLD) design with condensate recycle.
  • Noise and Heat Shielding: Acoustic panels and refractory insulation.

๐Ÿ“ 7. Engineering Standards and Codes

Discipline

Standard/Code

Pressure Vessels

ASME Boiler & Pressure Vessel Code

Electrical Design

IEC 60364, NEC

Safety

NFPA 86, OSHA, API RP 500

Environmental

ISO 14001, IFC Guidelines


๐Ÿงฎ 8. Plant Sizing and Space Requirement

  • Plot Size: Minimum 500 mยฒ
  • Utilities Required:
    • Power: ~60โ€“75 kW
    • Water: 2โ€“4 mยณ/day (non-potable)
    • Air: ~6 bar for instrument use
  • Building Height: 6โ€“8 m for reactor installation
  • Foundation: RCC with vibration-proof mounts for heavy units

๐Ÿ”„ 9. Flexibility and Modularity

  • Modular design allows scaling to 20โ€“50 TPD by parallel reactor trains.
  • Retrofit options for co-processing rubber, biomass, or multilayer plastics.

โœ… Conclusion

The proposed 10 TPD Plastic to Fuel Plant is technically and operationally feasible under standard engineering practices. The process utilizes mature pyrolysis technology, relies on widely available components, and adheres to international engineering codes. With proper design, the plant ensures reliable performance, environmental compliance, and scalability for future expansion.

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