How to turn plastic waste into diesel fuel cheaply

[Babataku]

Thanks Excalibur,

I intend to hold the reflux at about 220deg celc, i am not sure whether heating the reflux is neccessary, or the vapour heat will be enough with insulation? my worry is that if the reflux exceeds this temp, how will i cool it down back to 220deg??

Will be posting pictures this week, all materials should be with me tomorrow and i will start piecing it together.

What about storage issues?? i am a bit worried...will i have to look for some Anti-oxidants?

[Excalibur]

Babataku
Antioxidant tipped a few years ago. I haven't tried or heard of anyone using it.

Refux temperatures. The way I see it is:
...if temps are too high, there could be a wax problem or the fuel may be too heavy.
...if temps are too low, the fuel will be too light. Also making it will use up more energy.
So there is a "window" of temperature range that you need to find to suit your retort machine and feedstock. Once you get within this range, a small amount of trial&error is required to find the "sweet spot".

Re cooling of the reflux. I wondered if air cooling of the reflux vessel would help control temperature downward. The thought was to weld fins on, like motorcycle barrel fins. Then blow air across the fins at a velocity that stabilized temperature at the target. A variable speed fan would allow control of the cool rate.
Disclaimer, I haven't tried this exact remedy)

[rozier56]

Some clarification on terms used.
1.Distillation column: Tower with maybe a few baffels inserted and gas sent to condenser which is normally water or air cooled.
2.Fractionation column: Tower with plates at different heights/temps to remove distillate according to requirements of the products required.
3. Reflux column: Tower with baffels inserted,gas is then either returned to a point in this column,or passed through condenser and then returned to reflux column.
I note some folks talk about reflux columns, but their pic's don't show this.It is slightly confusing.

[AAS]

new project

Hi guys.
Been reading the blog for the last year or so, slowly building my plant, almost done. I'm from South Africa. I studies polymer science up to a masters degree in the in the early 2000's.

Added a view pics, will be running my first run in a week or so, will post results.

Kind Regards

[AAS]

new project

I would like to give some figures and would like to know how it sounds

Capacity of reactor is 900L, think I will get about 450kg of shredded mixed plastic mostly PE, or a mix of WMO and shredded plastic about 500kg

Energy used to heat reactor is 3phase electricity, total capacity of oven is 45kw, but presently only using 30kw (only using bottom 6 0f the 9 X 5Kw elements to start)

Dual condensers: primary is straight rods between reactor and storage tank/trap

Secondary condensor is the top third part of storage tank consisting of internal looped and cooled pipes positioned between metal flakes suspended between two metal grids.

Planning to make one combined fraction in the diesel range, depending on the specific density of the product I will insulate the reflux if needed.

Catalyst will be a locally sourced zeolite mixed into the wet batch.

Regards
AAS

[AAS]

new project

Only S/Steel used, minimum thickness of 10mm used on the lid, mechanical seals everywhere, pressure gauge installed, will be running at 400degrees.

Kind Regards

[SlyviaCoryell]

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[AAS]

new project

Post production fuel will be purified using a pabiodiesel 120 inverted centrifuge.

[Beyond Biodiesel]

Welcome AAS, looks like you have been busy, and made one of the best pyrolysis units posted here so far. The only recommendation I have is more uniform heating tends to increase heating rate which increases throughput. So, instead of turning off heating elements reduce the power going to each heating element by either wiring them in series or using several variacs, one for each heating wire, will allow you to reduce the watt density easily, so that you can spread those watts uniformly. Also, a hot plate at the bottom in the form of a coil of nichrome wire under your retort will spread those watts more uniformly while increasing the heating rate.

[AAS]

new project

Thank you beyond biodiesel, I'm hoping the stirrer will somewhat compensate and at least distribute the heat uniformly internally. More contact exposure and from the bottom makes sense, will use that in next prototype, cost and simplicity of building made me opt for the existing arrangement of elements.

The furnace ways about 2 tons and reactor about 500kg's so now that it's in position, it's staying there for now.

Regards
AAS

[Excalibur]

Welcome and very nice work!!

Wow, 30 -45kw!! How much can you get kw for? I looked at it when I first started and normal rates were 33c per kw.

Have you a schematic of the condensers? I'm always looking to learn, especially how to improve efficiency or recover heat.

Wishing you best of luck and watching progress with interest.

Thanks for sharing!

[Col]

Aas

Wow, look at you go! I recall someone mentioning galvalised material was not a good idea? The pipes going from the retort to the condenser look galvanised. Does anyone still see this as a problem? (tried the search function to find the notes but couldn't find any reference to galvanis(/z)ed)
What diameter is your reflux pipe? What a beast!
Looks like you're about to have some fun!
Col

[ndsunil]

Hi guys.
Been reading the blog for the last year or so, slowly building my plant, almost done. I'm from South Africa. I studies polymer science up to a masters degree in the in the early 2000's.

Added a view pics, will be running my first run in a week or so, will post results.

Kind Regards

Wonderful job ... How much that you have calculated to complete the reaction ?
This time shall decide your KW inputs . Any way a great and nice job .

[rozier56]

Hi AAS,Welcome to the site. Great to to have a fellow South African.I am based in cape town and would be happy to touch base with you to discuss the project.I too am a long way down the line and have run various prototypes.
Contact Derek;0824756959.
e-mail;mtrozier56@gmail.com

[AAS]

new project

Hi guys

The first condenser is straight forward. straight copper pipes with water around it.
I will add a picture of a schematic of the second condenser. The first condenser reduces most of the heat, the second causes precipitation (like a car driving in mist) the small molecules hit the metal, then another molecule hits that molecule an perhaps now combined they can precipitate out in liquid form.

Using an small evaporative cooler to cool the water.