How to turn plastic waste into diesel fuel cheaply

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V grove

Hello Kris ;
Thanks for the complement & I would like to thank our Grand Pa Jetijs again for creating such a wonderful forum .

Jetijs were are you nowadays, haven't heard from you LONG. Are you on a honeymoon ???

Now Kris your preparation is in the right direction & remember
'Sucess never come in one SHOT . You have to try Again & Again & Improvise accordingly.
Answers to your questions.
1) Your output pipe size is ok.
2) Diping pipe in Chilled water should be done , infact i would suggest that place your pipe in an 4"inch-oversize pipe having water inlet & outlet . Hang it vertically & Water coming in from the bottom inlet & the outlet is placed on top of the oversized pipe .
The efficiency of vapor condensing to liquid will double .
3) for removing liquid fuel from condensors you have to place a Gate-Valve at the bottom of the condensor.
remember one thing that for few runs normal gatewall or ball type valves will work but the material they are madeup are not much resistant to high temperature upto 400 celcius . There are special valves for this job U have to hunt for it .

4) Jetijs lid arrangement is very important I would say it is the heart of the reactor . The V-GROOVE male-female arrangement is very important . Double check it . I use to sit with the Lathe machinest & as soon as he says its ready I use to mark the upper lid with chalk & place it back on the lower portion & rotate it to confirm the Vogroove is perfect . I hope U got it, if not than just read these lines to your machinest he will understand it .

4) Your First TEST run should be with plain water only without putting CaoH even your reflux chamber should be empty . I did it to make sure that the unit is working properly.

a) No Vapor leakages specially from the Flange & pipe joints .
b) Heater+temperature control systems working properly .
c) Water vapors are properly condensing.
d) Second trial run you should do with waste motor oil (WMO) only .
Again no CaoH & reflux chamber EMPTY .

You will gain a lot of confidence if you follow this Golden path

When I started experimenting I was jobless for about an year & my first reactor used to catch FIRE as soon i hit the temerature 300 celcius the last fire went so strong it nearly burned my neighbors truck .
There was no one to guide me through I use to ponder whole night what to do next .
Alhamdullilah My 100 gallon baby is running perfectly & Iam getting serious inquiries from many countries to make a unit for them .
Infact I just signed an Joint-venture Agreement with a Getleman from Dubai to make a reactor for extracting Styrene Monomer from waste plastic .

You are lucky as so many people on this forum are here to guide You .

Wish you all the luck .
Go Ahead ...

Dear Asad,
Thanks for the guidance. Its better idea to make trials 1st with Water than with WMO n than with PP. Definitely I will proceed in the manner.
Surely your idea of placing big pipe over output pipe is good. I have done the same arrangement but it is horizantal. Hope it will work.
There are few points hope you can answer me.
A) I made U type of grove instead of V. The grove is about 2mm on bottom plate and male part is on top plate of same width but slightly more in height about 2.5mm. Hope this should nat be any problem.
B) I have fixed one Brass tube closed from bottom to fix Thermo couple on top plate of reactor. I hope I don't need tha same for Refluxor chamber.
C) About WMO I tried to search WMO with local automobile garages thay say it is the waste black color Engine Oil removed from Automobile Engines. Is it the same WMO. What they are asking for it os quite costly, about half the price of Diesel.
D) is it necessary to fix a Valve in outlet pipe. As local water Valve won't work at that temp. If necessary can I fix it after cooling pipe as temp will be low there.
Thanks again for the help.
Wish me good luck

[tc625]

Feedstock Recycling and Pyrolysis of Waste Plastics

I hope this book will help.

http://astro.elte.hu/~hetesizs/FFEK/...20Plastics.pdf

It was a good link as of last night.

http://astro.elte.hu/~hetesizs/FFEK/...20Plastics.pdf

I hope I did this right

[Asad Farooqui]

Your first trial

Dear Asad,
Thanks for the guidance. Its better idea to make trials 1st with Water than with WMO n than with PP. Definitely I will proceed in the manner.
Surely your idea of placing big pipe over output pipe is good. I have done the same arrangement but it is horizantal. Hope it will work.
There are few points hope you can answer me.
A) I made U type of grove instead of V. The grove is about 2mm on bottom plate and male part is on top plate of same width but slightly more in height about 2.5mm. Hope this should nat be any problem.
B) I have fixed one Brass tube closed from bottom to fix Thermo couple on top plate of reactor. I hope I don't need tha same for Refluxor chamber.
C) About WMO I tried to search WMO with local automobile garages thay say it is the waste black color Engine Oil removed from Automobile Engines. Is it the same WMO. What they are asking for it os quite costly, about half the price of Diesel.
D) is it necessary to fix a Valve in outlet pipe. As local water Valve won't work at that temp. If necessary can I fix it after cooling pipe as temp will be low there.
Thanks again for the help.
Wish me good luck

Hello ;
1) V-groove only, NO compromise .
The 2.5mm height of your groove is less increase it to 4mm .

2) For effective use of reflux chamber it is necessary to place a thermocouple close to the outlet . You have to control the vapor outlet temperature .

3) Yes WMO is the black engine oil discharged out of the cars .
For single try with WMO get it at any price, in UK it is 09 penny per litr .
Check other garages they might give you free/cheap .

4) There is no need for any valve in the outlet pipe .
Valve is needed at the bottom of the condensor & if your unit is a small one say upto 20-ltr or so than you don't even need it . You can drain out the oil at the end of the reaction .
My pilot unit of 20-ltr has no valves . My 100 gallon unit certainly has it .

[otpadnoulje]

Asad Farooqui, i would like to know can i put catalyst clay into liquid phase in reactor. Does anybody do it? Please, try it?

[imakebiodiesel]

Asad, I mixed up some biodiesel and some plastic diesel 50/50 and left it to stand overnight, There has been no separation but the mixture is a little cloudy. Both the ingredients were perfectly clear. Ill watch it for a few days and see if any sediments drops out.
In my limited experience clay catalyst will not work mixed into the molten plastic. What do you think Asad?

[tc625]

Fly ash catalyst

This guy uses fly ash.

http://www.netl.doe.gov/publications...ea/shchung.pdf

[Asad Farooqui]

Wvo + Wmo

Asad, I mixed up some biodiesel and some plastic diesel 50/50 and left it to stand overnight, There has been no separation but the mixture is a little cloudy. Both the ingredients were perfectly clear. Ill watch it for a few days and see if any sediments drops out.
In my limited experience clay catalyst will not work mixed into the molten plastic. What do you think Asad?

Hello ;
Thanks for testing it
HAZINESS is a sign of INCOMPATIBILITY .
Try a WVO/WMO=25/75 & let me know is it not hazy ? Can U run this ratio in an engine & check its performance ???

Liquid Phase Catalyst :
Yes there are many possibilities . I read a report that Activated-Bentonite clay can be added with HDPE-waste in the reactor in a ratio of 3:1 .
The reaction temperature can be dropped to 300 celcius.
I haven't tested it yet . I hope forum community can try it .

Nowadays iam conducting trial for extracting Styrene Monomer , had anyone tried it already ???

[congnghiah4]

mix WMO,WVO and Liquid Phase Catalyst

Hello ;
Thanks for testing it
HAZINESS is a sign of INCOMPATIBILITY .
Try a WVO/WMO=25/75 & let me know is it not hazy ? Can U run this ratio in an engine & check its performance ???

Liquid Phase Catalyst :
Yes there are many possibilities . I read a report that Activated-Bentonite clay can be added with HDPE-waste in the reactor in a ratio of 3:1 .
The reaction temperature can be dropped to 300 celcius.
I haven't tested it yet . I hope forum community can try it .

Nowadays iam conducting trial for extracting Styrene Monomer , had anyone tried it already ???

Hi asd, imakediesel
To the best of my knowledge, if the wmo and wvo mix run the reaction Distillation then not good.
although at first time is not see the phenomenon of phase separation but
24-48 hours after they re-distribution phase
If you want to mix above two stype , it must be done in two different
you much make,two new product finish then is mix. because wvo is biodiesel; WMO is diesel
Activated-Bentonite is not the catalyst in the liquid phase. It like clay structure, the structure bentonite there are hole Capillary when advertising in the liquid phase will take effect the catalytic

[white8]

I'm having a terrible time finding feedstock. I spoke with a recycler today and he has PE at $.35/lb which would work out to a little over $3.00 per gallon of fuel. Would the process work with asphalt roof shingles? I don't believe that anyone has found a use for them here yet.

[imakebiodiesel]

I believe the adding plastic diesel to biodiesel has lowered the cloud point of the mixture. I warmed a sample of the mixture in my workshop today. the starting temperature was 16C. At 28C the mixture became clearer, but not totally clear as I would expect. From this I suspect that biodiesel and plastic diesel are not compatible, at least not in cold temperatures.
Has anyone else tested a catalyst to see how much diesel it can produce before it is spent. Fibuslitero, you were using pumice, how well did it last?
In my small outfit 100 gms of clay catalyst yeilded 1.6 litres of usable fuel. After that the fuel became waxy and dark. The blocks of clay were biscuit coloured when they were new but were totally black all the way through when they were spent.
Asad, Ive no doubt if you add enough catalyst to the liquid phase it might have some effect but the gas phase is bound to be more efficient. In the example you quote it took 3 kilos of activated bentonite to process 1 kilo of plastic. That would be a very expensive way to produce fuel.

[aigu]

Hello all,

OK... did my first run with the heated condensers and got poor results; It seems that most of the gas goes all the way through all the condensers and out the bubbler. I tried shutting off the bubbler off and after a few minutes opened the valve in the first condenser and vapor rushed out, got in contact with the flames and some hairs on my arm disappeared... lol...

So now I am afraid of pressure build up if I shut the bubbler off (or keep it at a minimum opening) so that would not be an option although someone suggested that I should run a line from the last condenser to the catalyst (wouldn't that build up a lot of pressure?).

Perhaps the condensers need to be bigger or the temps are wrong or the condensers should have something inside (i.e. coils, plates). I really donīt have a clue so I would appreciate some help on this.

Cheers!

Temperatures I am using:
Reactor 400C.
Catalyst 220C.
First condenser: 150C.
Second Condenser: 80C.
Third Condenser: 20C.

[otpadnoulje]

I really donīt have a clue so I would appreciate some help on this.

Cheers!

Temperatures I am using:
Reactor 400C.
Catalyst 220C.
First condenser: 150C.
Second Condenser: 80C.
Third Condenser: 20C.

Please make draw of your plant, or photo.

[otpadnoulje]

I read a report that Activated-Bentonite clay can be added with HDPE-waste in the reactor in a ratio of 3:1 .

[/COLOR]

Are you sure about ratio? Is it 3:1 or 1:3 ?

[imakebiodiesel]

Aigu, dont block off the bubbler, if you do you have converted your reactor into a bomb. At these kind of temperatures it will take very little time to build up sufficient pressure to explode.
If all of your plastic is converting to vapour which will not condense at 20C then you are overcracking. However before you decide that that is the problem check the the temperatures in the condensers are accurate. How do you measure them?
Over cracking is usually caused by using commercial catalysts designed for more demanding tasks than we require. What catalyst are you using? Perhaps you are using too much. How much plastic are you processing and how much catalyst ? What type of plastic are you using.?

[aigu]

Please make draw of your plant, or photo.

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1. Propane tank
2. Reactor 370-400C
3. "Catalyst" (nothing inside yet) 220C
4. Condenser 150C
5. Condenser 80C
6. Condenser 20C
7. Bubbler