How to turn plastic waste into diesel fuel cheaply

[IHCUBMAN]

Asad, I have been reading this post for a long time and have been contemplating a similar system layout to the one you last posted. I am very impressed with your design I was wondering if a shaft could be mounted vertically in the feed reactor with auger flighting on the bottom half of the shaft extending into the output tube, when you need more material in the main reactor an electric motor starts to turn the shaft forcing the molten plastic into the other vessel.

A question for you, as long as you keep a certain amount of plastic in the feed reactor do you think you need a valve between the reactors or will the plastic work to keep the main reactor sealed from the air?

It looks as though you are going to use a furnace burner to start the reaction is that correct?

I was also having trouble figuring out the level sensing in the main reactor, could you touch on the o2 sensor idea a bit more? Are you going to compare temps of the senders to plastic temp or ?

I have been gathering materials and hope to start to build a unit soon. I hope this idea helps and appreciate any thoughts on my questions.

Keep up the good work.

Glenn

[nirajdevkota]

Jetijs

Hello Sir,
I Am Impressed With Your Idea.i Would Like To Help My Country Doing This And Saving My Country Power Crisis.if U Can Help Me To To Send The Full Details In My Mail I Will Go To Shop In India And Tell Them To Make For Me..please Give Me Details Of All Parts With Pics ..it Will Be My Pleasure To See U In This Website

[nirajdevkota]

hello sir

Hi Mart.
The quality of the fuel was already tested, it is about 90-95% diesel and 5-10% gasoline. This works great in liquid fuel burners. If you need it for a diesel engine, you just need to heat the fuel to abut 250 degrees till all gasoline evaporates and you now have pure diesel.

sir i would like to get the full details of the parts so that i can make myself over here in nepal..thank you

[Betopty]

read the whole post

sir i would like to get the full details of the parts so that i can make myself over here in nepal..thank you

Hi glad to have you here. If you read the whole post, you will have all the information you need.

[Jetijs]

sir i would like to get the full details of the parts so that i can make myself over here in nepal..thank you

Hi.
I am not manufacturing these units, I just share my experience. All the info you need is already outlined here in this topic, if you read through it, you will have all your answers and design ideas.
Thanks,
Jetijs

[Asad Farooqui]

feeding system

Asad, I have been reading this post for a long time and have been contemplating a similar system layout to the one you last posted. I am very impressed with your design I was wondering if a shaft could be mounted vertically in the feed reactor with auger flighting on the bottom half of the shaft extending into the output tube, when you need more material in the main reactor an electric motor starts to turn the shaft forcing the molten plastic into the other vessel.

Glenn

Hello Glenn ;

The pyro unit I designed for my client in USA doesnot need an auger type shaft to push the molten feedstock to the main reactor . It will flow by itself to the main reactor .

[dutchdivco]

Good to know

About pressure cookers having a metal to metal seal. Would work great for a small unit, and,... wondering if, for a LARGER unit, could cut the bottom out of the pressure cooker pan, and weld the pan to the side or top of a larger chamber, so the 'lid' could lock down on that.
This would give a viable option to the V-groove, seems to me. Another option to consider.

Funny, it seems like a lot of readers don't really grasp the concept of "open source". Perhaps because they want it spoon fed to them, they don't 'get' that jetsis is offering his experience freely, and encouraging them to take the 'raw material' knowledge he's presenting, and then work out their own system. But, He is NOT presenting a 'finished design', that they can simply take and build, nor is he presenting a finished product for them to buy.

So, again; READ thru this 'thread', from first post to current, several times.
If English isn't your first language, maybe 10 times. ALL the info you need is here; all the questions you have are answered. All the challenges to utilising this technology are covered, along with various creative ways to address or 'solve' these challenges. Then take this information, and, with SAFETY your top priority, figure out your own way of applying this technology, based on the resources you have available, and what your end goal is.

Different solutions are available, depending on whether you want to build a small system, just for experimenting, or try to make your own fuel to lower your fuel coists, or to get into this as a commercial enterprise.Its all up to YOU. Jim

[Asad Farooqui]

consultancy

So, again; READ thru this 'thread', from first post to current, several times.
If English isn't your first language, maybe 10 times. ALL the info you need is here; all the questions you have are answered.
Different solutions are available. Jim

Hello Jim ;
Well U are right most of the basic concepts for waste to liquid (WTL) are widely discussed on this forum .

Still some newcomers don't have the time or resources to go through the experimental work . And mind u it takes a lot of time & patience to do it.

Secondly some people don't have the right resources or they are very expensive in there country. One of my client insisted me to come to USA & make a WTL unit for him there, he has willing to cover all the expenses .
I just checked in USA it costs about $ 500/- to get a V-groove made comparatively it costs only $ 50/- in my country .
So the manufacturing costs in some countries gets too high & U have to make thinkgs again & again at the first time, this makes it more expensive.

I think so people like Jetijs should start a consultancy service .
Well I have already started consultancy service & Iam currently making WTL units for client .

If anyone interested he can contact me my e-mail
ahl_asadfarooqui@yahoo.com

[dutchdivco]

Asad

Based on the # of people posting variations of "Please tell me how to do this, with step by step instructions, parts lists, etc. i.e. wanting it on a 'silver platter', I would expect you will soon have a long waiting list of clients.

I was just trying to, once again, forestall someone posting a 'please do it for me' kind of post. Wish you well in your endeavor.I DO suspect, (as I live in the U.S., that I could probably find someone here to make a V-groove for less than $500. Sometimes you just have to 'shop around'.

On the other hand, I haven't actually tried, I just know there are often different prices for products and services, within a certain geographical area.
Jim

[tony steinke]

Hello Glenn ;

The pyro unit I designed for my client in USA doesnot need an auger type shaft to push the molten feedstock to the main reactor . It will flow by itself to the main reactor .

My experiments with PP and PE "flow" characteristics have resulted in the following: PP has very good flow, it takes nothing more than gravity and a little pitch to move it. PE on the other hand, is a completely different animal. No matter what temperature you heat it to, it maintains a peanut butter consistancy. Without an auger or a ram of some kind to force it, I don't understand how you intend to get it into the reactor. Can you please elaborate?

[IHCUBMAN]

Tony, I am still working all that out but I had planned on putting as much as I could in the main reactor and melting it. Then filling the melt reactor and feeding it into the main reactor probably with an auger. I have been trying to figure out how to control/ moniter the level in the main reactor so that it doesn't get over full. If I get that worked out then I can use something to control the fill rate of the main reactor and keep it full. then you could figure out the amount of plastic the catalyst will take (process effectively) and run that as a batch. Then it could be opened up, cleaned and restarted. I have a Beckett oil burner that I plan on using to get the process started and then use the gas and burner to keep the temps up. I thought about putting the char in the fire box also to provide more fuel.

I have the equipment to build most of the parts I need just having a problem finding the time right now to build them. Just trying to get a solid plan for when I can get started. I am also gathering the nessecary parts to build it. I have been reading this thread daily and find it very inspiring and helpful.

On another note Asad,you said one client wanted to do tires till he found out about the carbon black amounts. Since carbon black is flammable could it be used as fuel to heat the reactor? I thought about researching injecting powder in an air stream and burning it.

Well that's what I have so far.

Glenn

[Betopty]

I agree

Ait seems like a lot of readers don't really grasp the concept of "open source". Perhaps because they want it spoon fed to them, they don't 'get' that jetsis is offering his experience freely, and encouraging them to take the 'raw material' knowledge he's presenting, and then work out their own system.

I feel your pain Jim

[Betopty]

melt index

My experiments with PP and PE "flow" characteristics have resulted in the following: PP has very good flow, it takes nothing more than gravity and a little pitch to move it. PE on the other hand, is a completely different animal. No matter what temperature you heat it to, it maintains a peanut butter consistancy. Without an auger or a ram of some kind to force it, I don't understand how you intend to get it into the reactor. Can you please elaborate?

Hi Tony
Youve stumbled upon my same premise. The melt index of bagable and blow molded prastics is designed so they do not drip or move, while they ar being moulded or blown. This effect makes them un-flowable. You also have to remember you have some sort of low pressure in your rector (probably not more than 5 psi probably) but some pressure none the less.
This means not only that the plastic wont flow, due to melt index, but that the pressure of the reactor`s gases out, is greater than the plastic in. So unless Assad has found high melt index products, or altered his mix to obtain high melt index (mixing with waste oil was my first assumption) his mix will not flow inwards when he opens his gate, the reactor will fart out the hot gases and the material will not flow in. From the plans he has provided i can deduce no more.
ON the other hand I assume by his lack of information (as this has been asked several times) that he regards these informations as classified and we must all remember that he is not obliged to answer our questions as these details might be part of his knowhow. It is interesting none the less to speculate on the matter.

[Asad Farooqui]

feeding system

Hi Tony
ON the other hand I assume by his lack of information (as this has been asked several times) that he regards these informations as classified and we must all remember that he is not obliged to answer our questions as these details might be part of his knowhow. It is interesting none the less to speculate on the matter.

Hello ;
I was quite occupied with my work, spending almost 12-hours at work, that's why not able to answer promptly .

Well the feedstock flow ability as I said, should not be a problem .
You guys are quite right about the PE & PP flow ability .

My main feedstock is PP not PE . It's almost half the price than PE in my country . PP is about $300/- per ton & PE around $ 500-1000/- per ton .
Secondly my main liquid product is White Spirit (WS), & for it PP is ideal .

Still it is possible to add WMO upto 25% with PP to ensure good flow-ability.
I would recommend if U have to use PE not PP than try blending WMO . Iam quite sure it will solve the flowability problem .
Otherwise with 100% PE it is not advisable to use my design .

It would be more appropriate to connect a Screw-extruder with the main reactor .
I have a 3-D video of a similar design , if anyone like to see it he can e-mail me . i will send him my e-mail .
Sorry I don't know how to attach a video .

[Betopty]

Secondly my main liquid product is White Spirit (WS), & for it PP is ideal .

Hi Assad thank you for your clarification, and generosity in sharing your designs. After your clarification (at least from a mechanical and plastics only viewpoint)I believe your design is perfectly suited to your waste stock, saving an important amount of money on the auger requirements involved in other designs.
My only other doubt is how you will use the o2 sensors to achieve level control. Perhaps you could expand on that as well


I have great intrest in your Mineral spirit idea. I believe it is a marketable, much more expensive product than diesel (at least in My country), and requires little or no licencing compared to manufacturing/selling/distributing diesel

Looking over my notes I see You commented on this a while back specifying destillation temperatures of 65-69 C. What is your suggested reactor temperature? What is your estimated yield (kg of waste to liter of white spirits) using PP?


I believe this is a fabulous alternative