🛠️ Technical & Engineering Feasibility Study for 10 TPD Plastic to Fuel Plant

 

 📌 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.

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🧪 2. Applicable Science and Engineering Principles

• Thermal Decomposition:
  Pyrolysis is governed by thermochemical decomposition of polymers at 300–500°C 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.

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🏗️ 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: 350–450°C.
• Pressure: Slightly above atmospheric (~1–1.2 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.

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🧱 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

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🧾 5. Process Inputs & Outputs

Stream	Input/Output	Quantity (Daily)
Plastic Waste	Input	10,000 kg
Liquid Fuel	Output	~6,000–6,500 L
Non-condensable Gas	Output	~1,500–2,000 m³
Solid Char	Output	~1,000–1,200 kg

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🛡️ 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.

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📐 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

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🧮 8. Plant Sizing and Space Requirement

• Plot Size: Minimum 500 m²
• Utilities Required:
• Power: ~60–75 kW
• Water: 2–4 m³/day (non-potable)
• Air: ~6 bar for instrument use
• Building Height: 6–8 m for reactor installation
• Foundation: RCC with vibration-proof mounts for heavy units

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🔄 9. Flexibility and Modularity

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

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✅ 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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💰 Economic Feasibility and ROI Analysis of a 10 TPD Plastic to Fuel Plant

 

💰 Economic Feasibility and ROI Analysis of a 10 TPD Plastic to Fuel Plant

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🔧 1. Capital Expenditure (CAPEX)

Component	Estimated Cost (USD)
Pyrolysis Reactor (10 TPD)	$180,000
Condensation & Oil Recovery System	$50,000
Feedstock Handling & Shredding Unit	$35,000
Catalyst and Additives System	$15,000
Gas Scrubbing & Emission Control	$25,000
Instrumentation and PLC Control	$20,000
Utility Systems (Heater, Chillers)	$30,000
Civil Works & Installation	$45,000
Safety, Fire Protection & Permits	$20,000
Total CAPEX	$420,000

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⚙️ 2. Operating Expenditure (OPEX) per Month

Item	Monthly Cost (USD)
Labor (6 staff + 1 supervisor)	$5,500
Plastic Feedstock (free/donated)	$0
Catalyst & Chemicals	$1,500
Power & Fuel (10,000 kWh/month)	$2,000
Maintenance & Repairs	$1,200
Waste Disposal & Cleaning	$500
Insurance & Admin	$1,000
Total OPEX / month	$11,700

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🛢️ 3. Production Output (Daily)

• Plastic Input: 10,000 kg/day
• Oil Yield: ~65% → 6,500 liters/day
• Gas (used internally): ~20%
• Char (solid): ~10% → used as solid fuel

Monthly Oil Production:
6,500 L/day × 26 days = 169,000 liters

Selling Price: $0.60–0.75 per liter (average: $0.65)
Monthly Revenue:
169,000 L × $0.65 = $109,850

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📊 4. Gross Profit & ROI

Metric	Value (USD)
Monthly Revenue	$109,850
Monthly OPEX	$11,700
Gross Profit	$98,150
Payback Period (CAPEX ÷ Profit)	~4.3 months
Annual Profit (est.)	> $1.1 million

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📈 5. ROI Sensitivity (Oil Price)

Oil Price (USD/L)	Monthly Revenue	Payback Period
$0.50	$84,500	~6 months
$0.65 (avg)	$109,850	~4.3 months
$0.80	$135,200	~3.1 months

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🌍 6. Comparative Cost per Output Unit

Country	Oil Yield	Average Market Rate (USD/L)	Operating Cost	Profit Margin
India	60%	$0.55	Low	Moderate
USA	68%	$0.70	Medium	High
Indonesia	62%	$0.65	Low	High
Kenya	55%	$0.45	Very Low	Moderate

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📌 7. Financial Considerations

• Subsidies & Carbon Credits: Depending on country policies, up to $50–$100/ton may be credited under carbon offset markets.
• Byproduct Utilization: Char can be monetized or used internally as a supplementary fuel.
• Tax & Import Relief: Machinery often eligible for import tax waiver under environmental/renewable project incentives.

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🔒 8. Risk Factors & Mitigation

Risk	Mitigation Strategy
Fluctuation in oil prices	Diversify output (e.g., wax, char)
Feedstock contamination	Pre-sorting & washing system
Catalyst degradation	Regular analysis, replacement cycle
Regulatory changes	Ensure permits, follow environmental codes

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✅ Conclusion

With proper design, sourcing, and market linkage, a 10 TPD Plastic-to-Fuel Plant offers a highly profitable model with a short ROI period (<6 months) and strong sustainability value. This technology represents not only a waste management solution but also an economically viable renewable fuel enterprise.

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