WASTE / SCRAP PLASTIC RECYCLING SYSTEM
THE OBTAINING OF VALUABLE MATERIALS (OIL or FUEL) FROM WASTE/SCRAP PLASTIC
|
|
|
|
|
|
|
The bunker oil and coal can be obtained from waste/scrap
plastics. |
|
|
1. In the industry and waste plastic in the life
trash, allows several dozens kind of waste materials simultaneously to exist
(for
instance: PP, PE, is mixed together).
2. Scrap rubber tire
3. Waste electric cable skin.
4. Waste crude oil.
5. Waste PMMA (polymethyl acrylic acid methyl ester) regenerates.
FEASIBILITY STUDY REPORT ON REFINING OIL FROM SCRAP PLASTIC
I. Background and Significance of the Project
Along with the rapid development of the plastic industry, the plastic product has been applied more and more broadly. And have seeped into national economy of each domain and in people's daily life. It can be said that, any kind of other materials have not had the more widespread usage than plastic. The plastic by its own unique performance, like the quality light, the specific tenacity high, easily to process takes shape, the outstanding electric insulation, the heat insulation and bears chemistry corrosively and so on, has become one of modern industry prop materials, is playing the more and more vital role in the national economy. However, precisely because the plastic’s certain outstanding performance, cause that it is not easy to be rotten after the use (or called expense). The plastic accumulates over a long period of time, seriously has affected Earth's ecological environment, and has aroused common people's enormous interest. At present the global plastic products’ total quantity has been already ultra a hundred million tons, our country plastic products have been also nearly thousand tons, and also yearly rate grows by 13%. The scrap and used plastic total quantity also suddenly will grow, the environment and the development contradiction will be more and more prominent, thus has appeared urgently to govern the plastic reject.
The plastic rejects’ the simplest processing method is filled in buries with simply burns down. Filled in buries need to take the very many precious land resource; moreover, also can pollute the peripheral environment and the groundwater system; Simply burn-down also can discharge the noxious gas and the residual, simultaneously, if the massive combustion heat is unable to be recycled when worn out plastic burning to produce to create the energy that will be huge waste. These two ways are two non- brilliant plans. Therefore, how to process the plastic trash also become the various countries’ and all levels of government’s studies and the attention topic together. Since the 1990s, domestic researches which have transformed the scrap plastic for the bunker oil start to receive the widespread value.
Japanese Mitsubishi heavy industry development decomposition trough production bunker oil craft
First breaks the scrap plastic into the certain size, dried, then send them into the fusing slot by hopper (material chute) (300°C -350°C) to fuse, again sends them into decomposition slot (400°C -500°C) to carry on the slow decomposition, each slot depends on the hot blast to heat up. The tar or wax high ignition point material must be returned to decomposition slot to decompose into low molecule matter through the pyrolysis after the condenser condenses to separation. The low-point ingredient steam is separated into condensate liquid and uncoagulates gas in the condenser; the condensate liquid may recycle the oil class again after the oil-water separator separates. This kind of oil is low-viscosity, high calorific capacity, solidification point below zero degree Celsius, but broadly burning point, very low kindling point, and is one kind of high quality bunker oil, when using, it is best that can remove the low ignition-point ingredient. The uncoagulate gaseous compound does not exit after the absorption tower and became the Hydrogen chloride that be possible to be as the fue. Part of the recycled oil and gas can be possible to serve as the energy to each slot to heat up.
German Hamburg University develops waste plastic fluid bed thermal decomposition for bunker oil reactor
The scrap and used plastic from hopper flows out, transports by the screw-conveyor feeder into the electric heating reactor, fluidization level 20M is approximately deep. Each hour needs the 50L liquefaction to heat up, the thermal decomposition gas removes dust in the electric power dust remover, again partial fluidity in depth chiller, the gas that has not been possible to condensation returns to the reactor as the liquefied medium to use again.
American Kentucky University fuel chemist Ban Dita and others to invention has done with the zeolite molecular sieve as activator to put each kind of plastic into the sand-covering utensil to mix, then pours this kind of serum into the reactor, the hydrogenation pressurized, finally heated up again to make the high polymer plastic decompose into the high-grade bunker oil.
Above three overseas have the representative waste plastic oil-converting equipment, which may achieve respective national environmental protection request on production process of waste water, waste gas and waste residua, but investments are all above 2.5 million USD. The daily output only has 5 ton bunker oil. That is unable to promote, and does not have the commercial value.
Nowadays, the mainframe of the oil producing equipments which used to extracting oil from scrap plastic mainly adopt vertical fixed processor. The process can be described as follow,
Firstly, we should artificially put the scrap plastic from the top of the Split Processor, then seals up the material inlet. And the plastics are slowly heated at the bottom of the processor with coal, or wood as its fuels. The Split Processor has a capacity of 5 m3. For putting one ton of scrap tyres in, the recycling period generally is 12 hours. After finish this period, we should keep stopping for 12 hours to allow the fully cooling of the Processor.
Then open the outlet which is at the bottom of the Processor, discharge the residua, the next cycle follows.
The domestic vertical fixed oil refining Processor has disadvantages. The waste water, waste gas, and residues produced during the process can’t reach the requirements of environmental protection. In addition, the yield is low, not allowing continuous production. Only by combining several Processors together can get profits.
We cooperation with medical project design institute expert team, on the basis of other peoples' studies, enhance advantages and avoid disadvantages, base ourselves upon actual national condition of the producing technology. Through many years’ technology researching, we design and promote our equipment series refining equipments.
II. Several characteristics of the streamlined series refining equipment
1. Each set of equipment are composed by seven parts:
a. main engine horizontal type revolving split processor.
b. feeding-in system.
c. automatic removed the dregs system.
d. central electrically controlled system.
e. condensation system.
f. fuel gas heating system (waste gas processing system).
g. flue dust removal system.
2. Domestic pioneer of this technology
a. Entire equipment’s production entire process is running in the smokeless, tasteless environment, the environmental protection effect is good.
b. Does not need traditional two fractionation craft, with rotary processor may makes the fluidity-well transparent waste plastic oil, may large scale enhance the attachment value of the terminal product and reduces the production cost.
c. In in its key installment decomposition processor design, has thoroughly overcome the disadvantages of the domestic present vertical flat base split processor, such as bottom partial being heated non-uniformity, easy to break, low output, short service-life is short and so on, the main engine uses horizontal-type 360°C structure-1.2 R/M
d. Fast practical feed-in and discharge system. The highest feed-in quantity of the 3rd system every 24 hour achieved 12 tons, Discharge time for 3 tons carbon black only needs 90 minutes. The highest feed-in amount of the integral unit equipment every 24 hours achieves 36 tons.
e. Highly effective gas heating system. In the process of refining oil, after the gas is heated up to 150°C, it will produce a large amount of unliquefied gas-CH4 & C4H8 , which can’t be formed at normal temperature, normal pressure. If those gases have been fully burning by the specific designed gas nozzle, they can produce a great amount of energy and economize resources. Take the bunker coal as the example, the 3rd system equipment when it does not have the fuel gas as combustion-supporting, every 24 hours need 1.2 tons coals. After the fuel gas aid combustion, every 24 hour need 0.4 tons coal, which enhances production efficiency in the large scale and reduced the fuel cost?
f. Flue dust catcher system. It matches the bidirectional water impact type tornado dust removal room, may guarantee a smoke amount that export to discharge achieve the national level discharges standard.
3. The company pledged that, each kind of series equipment we sell have the consummation the post-sale service, a warranty period year, that thoroughly settle down customer extra worries.
III. Product and Raw Material Market
Since along with world economics progressing by leaps and bounds, the petroleum scarce tendency has grown day by day, enters for the 90's, the energy has become the primary factor that restricts various countries economy development, As the research speaking, the petroleum on global land will be exhausted within 15 years. Seeking the new energy has become the various countries’ matter of concern. In our country, we have massive land, large population. With the rapid development of Market Economic, vehicle and machine become more and more popular, the requirement of oil market unceasing grows, our country have become petroleum-import country from petroleum-export country. In 2006 the higher authority half year, the news which announces according to the Chinese Petrochemistry group, we eliminate the home production of the crude oil, but also must import 80 million barrels crude oils overseas, can satisfy the demand of the domestic market. After enters 2006, the international crude oil price rises repeatedly, each barrel crude oil have broke through 70 US dollars/barrels (OPEC in 2006 May quoted price). Then whether the raw material of refines oil can guarantee the origin?
For instance Henan Province, May every year recycles 4 million ton scrap plastic from trash and the recycling company. With the development of the industry and the transportation shipping industry, the massive used oil is also urgently needed to process.
The consumes the chemical fertilizer, the phosphate fertilizer, the cement every year and so on each kind weaves the bag, each kind of color plastic film, fast-food box, froth package blanket, each kind of food packing membrane, bottle, box, each kind of scrap rubber, plastic product, used oil, their total quantity approximately above 12,000 tons, therefore, a county establishes the refineries for a four year to process 1,500 tons waste plastics. The raw material is without worries.
IV. Main technical characteristic
1. This achievement essential equipment – split processor adopts the horizontal type revolving structure, the catalyzed split craft and the product chemistry extract technology.
2. Provides the environmental protection equipment is perfect. For instance waste gas burner and smoke dust removal room.
3. Adopts the simple chemistry method, has solved the product color and the unusual smell.
4. The oil extraction rate of the pure waste plastic is not lower than 50%
5. This equipment design is reasonable, manufacture craft is advanced, high automaticity, and the complete safety equipment
6. Versatility, one machine multipurpose.
V. The oil-refining processor suit product and the profession
1. In the industry and waste plastic in the life trash, allows several dozens kind of waste materials simultaneously to exist (for instance: PP, PE, is mixed together).
2. Used oil. For instance: Waste diesel oil machine oil, waste oil, waste deisel oil and so on.
3. Scrap rubber tire
4. Waste electric cable skin.
5. Waste crude oil.
6. Waste PMMA (polymethyl acrylic acid methyl ester) regenerates.
Vý. The technical process
Does not have to get rid of silt, moisture content, iron wire impurity and so on from the scrap plastic, directly loads in the rotary system high temperature atmospheric pressure split processor, catalyses, heats up, distils oil steam, the oil gas through the condenser, the liquefied part condense into the oil mixture, and the unliquefied part holds through the fuel gas system into the processor bottom to burn.
VII. Security
The main equipment is of high safety. The phase of the unliquefizable waste gas produced during the process is alkyl from C1 to C4, which is dangerous when burning directly. In our process, it is transferred first through a water close device and a safety device- burning air muzzle. Before burning, we should ensure the safety of production.
VIII. Environment protective
Dispose waste gas, liquid, and residua in the process:
1. Waste gas: Transferred through two safety device: water close &burning air nozzle. Fully burnt, not only eliminated pollutant but also minimized the quantity of fuels.
2. Waste liquid: Produced waste acidic water in the process of oil disposing (50kg process from 1 ton of oil easy to process for small quantity). counteract the liquid by alkalescent liquid solution. After three stage of filtration, the litmusless waste water was introduced to evaporator(use the heat of the flue of main processor as its heating resource)
3. Waste solid. The solid residua will be left after the catalyst splitting from scrap plastic, approximately composes the waste plastic weight about 5% to 10%. Its main component is the thick black carbon. It can be the raw material of the production industry of black carbon. Also could be mixed with the pulverized coal ash which produces for the raw material thermal power plant, also could be the raw material of manufacture pulverized coal ash brick (one kind of environmental protection building material).
IX. Economical benefit analysis
1. Equipment technique parameter
|
No. |
Project |
Content |
||
|
1 |
Equipment model |
System-2 |
System-5 |
System-8 |
|
2 |
Material |
Scrap Plastic |
Scrap Plastic |
Scrap Plastic |
|
3 |
structure |
Horizontal type revolves |
horizontal type revolves |
horizontal type revolves |
|
4 |
24 hours’ process loads |
4 ton row material |
6 ton row material |
12 ton row material |
|
5 |
Oil produce mass |
2 ton Bunker oil |
3 ton Bunker oil |
6 ton Bunker oil |
|
6 |
Work pressure |
Normal |
Normal |
Normal |
|
7 |
Main engine rotational speed |
1.2 R/M |
1.2 R/M |
1.2 R/M |
|
8 |
Provided power |
3.0kw |
3.0kw |
5.5 kw |
|
9 |
Coolant conditions |
Water |
Water |
Water |
|
10 |
Cooling water consumption quantity (T/h) |
2.5 |
2.5 |
2.5 |
|
11 |
Type of drive |
Chain drive |
annular gear drive |
annular gear drive |
|
12 |
Type of installation |
With foundation |
With foundation |
With foundation |
|
13 |
Noise dB(A) |
≤85 |
≤85 |
≤85 |
|
14 |
Main engine outlook size (long * width * high) |
3000×2000×2650 |
4000×2300×2650 |
6000×3000×2950 |
|
15 |
Main engine weight |
2600 |
4500 |
8000 |
|
16 |
Production cycle |
20 days |
20 days |
20 days |
2. Plant 450m2, including simple shed made of asbestine tile 70m2 and 300m2 inventory & auxiliary area.
3. Production cost (raw material as scrap plastic, equipment as System-5)
System-2 Economical analysis:
a. 6 tons waste plastic lives trash (oil extraction rate 50%) 6 ton * 38.7 USD/ton = 232.2 USD
b. Coal 300 kilogram 25.91 USD,
c. Water and electricity 25.91 USD,
d. The catalyst, chemicals 25.91 USD
e. Worker wages 30 USD/day
f. The equipment depreciation fee 2 USD
g. The tax (note) environmental protection project tax-free
h. Other 7.5 USD
i. Equals: 323.52 USD /day
j. The daily production leave the computation (to count the System-2 equipment daily production) It could be retracted oil for 3,000 kilograms by the System-5 equipment, needs the life trash plastic 6 tons.
k. Gross profit
End product NO. 0 diesel oil’s present values is 1 USD/kg.
The produced bunker oil may substitute No. 0 diesel oil to use on the fuel gas spray nozzle which the industry used to heat up. Produced bunker oil by each kilogram 1 USD computations.
As System- 5
Daily turnovers are 3000*1= 3000 USD
Daily profit: 3000 USD/day – 323.52/day = 2676.48 USD/day
Each month profit: 2676.48/day *25 the day =66912 USD
Profit per annums: (according to twelve months computations) 802944 USD
X. Conclusion
The analysis above proved: Extract oil from scrap plastic can get profit from waste, and is both in favor of people & nation. It is feasible in technology with small amount of investment, high availability of materials, short recovery period and with bright future, is the ideal choice of investing.