Project Profile for conversion of plastic

8/10/2019 Project Profile for conversion of plastic

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Project Profile

For

Conversion of Waste PlasticInto

Activated carbon & Industrial Fuel

(PROCESSING CAPACITY: 1 TPD)

Prepared By

Amol Kulkarni

Email: [email protected]



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Index

A) Introduction 3

B) Products to be manufactured 4

C) Market potential 4

D) Licenses for manufacture, storage and sale 4

E) Production capacity 4

F) Raw materials 5

G) The fuel standards 5

H) Applications of crude oil or industrial fuel 5

I) Technology and manufacturing process 6

J) Advantages of the manufacturing process 6

K) Building 6

L) Plant and machinery cost 7

M) Quality control laboratory equipments 7

N) Production cost for crude oil or industrial fuel 8

O) Project cost 9

P) Profitability analysis 10

Q) Annexure I 11

R) Annexure II 12



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A) Introduction:

For many years, various methods are tried and tested for processing of

waste plastic. The plastic materials are recycled and low value products areprepared. Plastic materials which cannot be recycled are usually dumped intoundesirable landfill.

Worldwide almost 20% of the waste stream is plastic, most of which still

ends up in landfill or at worst it is incinerated. This is a terrible waste of avaluable resource containing a high level of latent energy.

In recent year this practice has become less and less desirable due toopposition from Government and environmentally conscious community

groups. The value of plastics going to landfill is showing a marginal reductiondespite extensive community awareness and education programs.

Research Centre for Fuel Generation (RCFG) has conducted successful

300 successful pilot trials and commercial trials for conversion of waste plasticmaterials into high grade industrial fuel. The system uses liquefaction,

pyrolysis and the catalytic breakdown of plastic materials and conversion intoindustrial fuel and gases. The system can handle the majority of plastic

materials that are currently being sent to landfill or which have a low recyclevalue.

Catalytic conversion of waste plastic into high value product is asuperior method of reusing this valuable resource.

The distillate fuel is an excellent fuel and can be used for

1) Diesel electrical generators2) Diesel burners / stoves

3) Boilers4) Hot air generators

5) Hot water generators6) Diesel pumps

The distillate can be further fractionated into fuels as under and can be

used in automobiles.1) Petrol

2) Kerosene

3) Diesel



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B) Products to be manufactured:

Following products shall be manufactured from waste plastic

1) Crude oil2) Petroleum Gases3) Activated carbon

C) Market Potential:

There is great market potential for there fuels, as these can be sold atabout 25% less prices. The potential buyers shall be as under:

1) Industries having Boilers.

2) Industries having electric generators.3) Hotels and Resorts having electric generators and diesel stoves.

4) Construction companies having heavy machinery.5) Farmers using diesel pumps.

6) Indian Oil Corporation7) Bharat Petroleum

8) Hindustan Petroleum9) Indian Railways

10) Shops having electric generators11) Domestic people having electric generators

12) Establishments having electric generators

13) State transport corporations14) Local / City transports corporations15) Logistics companies.

D) Licenses for manufacture, storage and sale:

No license is required for manufacture of crude oil.For further refining of the petroleum products, application for mini refinery

should be submitted to “Petroleum and Explosive Safety Organization”(PESO), Nagpur (Maharashtra). In addition license for storage should be

obtained from District Authority for storage above 25,000 liters.

E) Production Capacity:

Daily 1000 kg. waste plastic shall be processed per day in 3 shifts. On

and average, 700 liters of fuel is obtained from 1000 kg. municipal plasticwaste.



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F) Raw Materials:

The raw materials include following:

1) Polyethylene: Buckets, drums, Chapels, sandal, bottles, plasticparts, carry bags etc.

2) Polypropylene: Pipe fitting, filter cloths etc.

3) Polyamide: Nylon ropes

4) Polyvinyl Chloride (PVC): PVC pipes and fittings

5) Polystyrene: Cloths and fiber

6) Rubber: Tires, automobile parts

7) Electronic Goods: Telephone sets, computers, keyboards, monitorslaptops, electronic devices etc.

G) The Fuel Standards:

The fuels manufactured by processing of waste plastics will comply with

any statutory requirements or standards anywhere in the world. The key

indicators include flash point, viscosity, density etc. are within specifiedstandards for fuel.

The test report of the crude oil or industrial fuel obtained by plasticprocessing is attached as annexure II.

H) Applications of the crude oil/industrial fuel:

Filtered crude oil can be used in:

a) boilers (replacement for LDO and furnace oil)b) electric generators,

c) furnaces,d) diesel stoves in hotels and food industries,

e) hot air generators,f) hot water generators,

The purified fuels are suitable for all engines including road enginessuch as trucks, buses, cars, motorcycle, as well as heavy machinery. The

diesel obtained by plastic process can replace virgin diesel fuel.



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I) Technology and manufacturing process:

Research Centre for Fuel Generation (RCFG) has developed innovative

technology for cracking of plastics by inventing a new catalyst which cracksthe plastic more efficiently in short duration and the conversion of 1000 kg. of

mixed plastic gives about 700 liters crude oil or industrial fuel. In addition weget about 15% hydrocarbon gas and about 80 kg. carbon black. 80 kg. carbon

black can be converted to 50 kg. activated carbon.

The technology developed is tested over the period of one year and iseconomically viable.

J) Advantages of the manufacturing process:

1) Problem of disposal of waste plastic is solved.

2) Waste plastic is converted into high value fuels.

3) Environmental pollution is controlled.

4) Industrial and automobile fuel requirement shall be fulfilled to someextent at lower price.

5) No pollutants are created during cracking of plastics.

6) Any type of plastic or rubber can be proceed and converted into fuel.

7) The crude oil and the gas can be used for generation of electricity.

K) Building(Shed):

100 Sq.Mtrs.

Cost of shed = 100 X Rs. 6000 = Rs.6,00,000/-

L) Plant and Machinery Cost:

Qty Description and Specifications

2 Conveyor for shredded plastic / rubber materials for feeding melting machine

2 Horizontal reactor screw type, processing capacity 110 kg. rubber or plasticprocessing per hour with stirrer, condenser and receiver

1 Cooling tower: 100TR



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1 Sparkler Filter: 8”dia X 8 plates 1 HP

1 Gas collection tank with floating hood, M.S. 1,000 L

1 set Machinery for manufacture of activated carbon from carbon black

1 set Pipe fittings, process pumps and electrical fittings with control panel

1 Electricity generation set 40 KVA

1 set Laboratory glassware and equipments

Cost of machinery = Rs. 28,00,000/-

+ Installation and commissioning Charges = Rs. 2,00,000/-= Rs. 30,00,000/-

Note: Taxes as applicable extra

M) R. & D. AND Quality Control Laboratory Equipments:

1. Specific gravity apparatus2. Hot Air blower

3. Analytical balance

4. Hot plate5. Glass distillation Unit6. Water bath

7. Laboratory stirrer

N) Production cost for crude oil or industrial fuel:

Production cost per liter of crude oil:

Raw material: 1000 kg.

(mixed plastic waste) @ Rs. 5 per kg. 5,000

Chemicals /catalyst cost 1,000

Processing cost (electrical) NIL

Fuel cost NIL

Total Production cost for 700 liters crude

oil 6,000

Administrative cost + salaries 3,040



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(Rs. 76000/25 days)

Total production cost for 700 liters 9,040

Production cost per liter of crude oil /

industrial fuel(Rs. 9040/700L) 12.91Interest on capital investment / liter

(Rs. 493050/210000 liters) 02.34Depreciation on fixed assets / liter

(Rs. 282500/210000 liters) 01.34Production cost per liter of fuel 16.59

Production cost per kg. of activated carbon:

Raw material: 80 kg.

(carbon black as by-product) NILChemicals cost 80

Processing cost (electrical) NIL

Fuel cost NIL

Total Production cost for 50 kg. activated

carbon 80

Production cost per kg. of Activatedcarbon 01.60

O) Project cost:

Basis:Products to be manufactured1) Crude oil 17,500 liters per month or 2,10,000 liters per year

2) Activated carbon 1,250 kg. per month or 15,000 kg. per year

Sr.No. PARTICULARS Rs. Rs. Rs.

A FIXED ASSETS

1

Machinery + Pipe fittings +Installation etc.

(As per list enclosed in K above) 30,00,000

2 Land (10000 sq.ft.) NIL

3 Factory shed (100 sq. Meters@ Rs. 3000/- per sq meter) 6,00,000

4Lab. Equipments, Furniture &Fixtures 25,000

Total Fixed assets: 36,25,000 36,25,000





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P) Profitability analysis:

1) Rate of return = (Profit per annum / Total capital investment) x 100

= (3242100/4087000) X 100= 79.33 %

2) Break Even Point = [Fixed cost/(Fixed cost + Profit per annum)] x 100

= [2161550/ (2161550 + 3242100)] X 100

= [2161550/ 5403650] X 100

= 40.00 %

Fixed cost =

Depreciation on fixed assets

@ 10% pa = Rs. 282500

+ Bank interest @ 15 % p.a. = Rs. 493050

+ Recurring cost for 6 months = Rs. 1386000

------------------

Rs. 2161550



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Process Flow Chart

Conversion of Waste Plastic into Industrial FuelProcess Machine Material Balance

(5%Variable depending on

Collection of waste plastic quality of Raw material and catalyst)

Transportation of plastic

waste to factory

1000kg of plastic waste as

input

Cutting Cutter 1000kg of cut plastic waste

Shredding of plastic Plastic Shredder 1000kg of shredded plastic

Plastic meltingPlastic Melting machine

screw type1000L of molten Plastic

Plastic evaporation Reactor Plastic Vapours

Catalytic cracking of plastic

vapours

Catalyst chamber attached

to reactorsFuel in Vapour form

CondensationCondenser attached to

Catalyst chamber

Liquid Hydrocarbon Fuel

700L + Hydrocarbon gases

In-line storage HDPE storage tank

Industrial Fuel 700 L

(Mixture of Petrol, Kerosene

and Diesel)

FiltrationSparkler Filter Filtered Crude oil

Storage Gas collection tank Hydrocarbon Gases



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U) Annexure II:Analysis report of crude oil / industrial fuel from waste plastic

SR.NO.

TEST METHOD OFTESTING

RESULT

1 Density at @150 C ASTM D 4052:2002 0.7930 gm/ml

2 Acidity (mg KOH/gm) ASTM D 974:2002 0.76

3 API Gravity @ 600 F ASTM D 1298:1999 46.67

4 Flash Point COC ASTM D 92-05a <400 C

5 Kinematic viscosity @ 400 C ASTM D 445:2005 2.149 mm2 /s

6 Colour ASTM D 1500:2004a D 8

7 Conradson Carbon residue ASTM D 189:2005 0.010% (wt)

8 Asphaltine content ASTM D 3279:2001 0.21% (wt)

9 Ash Content ASTM D 482:2003 < 0.01% (wt)10 Calculated carbon aromatic

indexISO 8217 :1996 763.4

11 Pour Point ASTM D 97-05a - 40 C

12 Sediment by extraction ASTM D 473:2002 0.012 (wt)

13 Specific gravity @ 150 C ASTM D 4052:2002 0.7932

14 Sulphur content ASTM D 4094:2003 75 ppm

15 Water by distillation ASTM D 95-05el < 0.05% (vol)

16 Colorific value ASTM D 240 cal/g 10000

17 Distillation range ASTM D 86:04 b

Initial boiling point 71.00

C05% Recovery 110.00 C

10% Recovery 141.00 C








85% Recovery 380.00

C90% Recovery 390.00 C

Total Recovery 90% (vol)



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Project Profile for conversion of plastic