MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION, MUMBAI

A
MICRO-PROJECT REPORT

ON

“BIODIESEL FROM PLASTIC WASTE”

Submitted By

Mr. Prathmesh Balasaheb Badhe 2015600240

Mr. Omkar Balasaheb Bankar 2015600267
Mr. Govind Bhausaheb Tambade 2015600264

Under The Guidance

Of
Prof. P.D.Kotkar

DEPARTMENT OF MECHANICAL ENGINEERING

ASHOK INSTITUTE OF ENGINEERING & TECHNOLOGY
POLYTECHNIC, ASHOKNAGAR.
 ASHOK INSTITUTE OF ENGINEERING & TECHNOLOGY

POLYTECHNIC, ASHOKNAGAR

CERTIFICATE
This is to certify that the micro-Project work Entitled

“BIODIESEL FROM PLASTIC WASTE”

Submitted by
Mr. Prathmesh Balasaheb Badhe 2015600240
Mr. Omkar Balasaheb Bankar 2015600267
Mr. Govind Bhausaheb Tambade 2015600264

As partial fulfilment of Diploma course in “Mechanical Engineering” under

the Maharashtra State Board of Technical Education, Mumbai During Academic
year 2021-2022 Project work has been assessed by us and we are satisfied that the same
is up to the standard envisaged for the level of course, and that the micro-project work
may be presented to internal examiner.

Prof. P.D. Kotkar Prof. N.V. Pawar

(Project Guide) (H.O.D.)

Internal Examiner Prof. A.P. Shinde

(Principal)
 ASHOK INSTITUTE OF ENGINEERING &
TECHNOLOGY POLYTECHNIC, ASHOKNAGAR
2021-2022

“SUBMISSION”

We are the student of third year diploma in “MECHANICAL ENGINEERING” humbly

submit our project report has the partial fulfilment of MSBTE Mumbai from July
Feb.2022 to June 2022
Under the guidance of Prof. P.D.Kotkar we have done this project with our own skill and
that we have copied the report or its any report part from any other literature in contravention to
academic ethics.

Name Of Student Seat No. Signature

Mr. Prathmesh Balasaheb Badhe 352898

Mr. Omkar Balasaheb Bankar 352917

Mr. Govind Bhausaheb Tambade 352914

 ACKNOWLEDGEMENT

Guidance is the key factor for achieving the goals. No micro-project can be completed without
correct help from experts, in the field. At this point we wish to express our gratitude towards those
who have made our project successful.

We are extremely thankful to our project guide Prof. P.D. KOTKAR Our endure without his
constant support and encouragement would not have been possible.

We are also thankful to Prof. N.V. Pawar (HOD Mechanical Engineering) for allowing us to
do work on this project, which termed beneficial to us. We are also thankful to the staff of the
department and all those who have directly or indirectly helped us in execution of our micro- project.

Mr. Prathmesh Balasaheb Badhe

Mr. Omkar Balasaheb Bankar

Mr. Govind Bhausaheb Tambade

 ASHOK INSTITUTE OF ENGINEERING & TECHNOLOGY
POLYTECHNIC, ASHOKNAGAR
2021-2022

DECLARATION
We undersigned, hereby declare that we have completed and written the micro-project report
entitled “BIODIESEL FROM PLASTIC WASTE” on our own. This is our original work and it is not
previously submitted for the award of any degree or diploma or similar title in any other examining
body or university as per our knowledge.

Name Of Student Enrollment Signature

No
Mr. Prathmesh Balasaheb Badhe 2015600240

Mr. Omkar Balasaheb Bankar 2015600267

Mr. Govind Bhausaheb Tambade 2015600264

 CONTENTS

SR.NO. TITLE PAGE

NO.

CERTIFICATE

DECLARATION

1. INTRODUCTION 2.

1.1 PLASTICS 2.

1.2 TARGET WASTE PLASTICS 3.

2. CLASSIFICATION OF PLASTICS 4.

3. METHODOLOGY 5.

3.1 PYROLYSIS 5.

CATALYTIC CRACKING OF POLYFINS

3.2 6.

MAIN DEVICES USED IN THE PROCESS

4. 7.

4.1 ADVANTAGES 9.

5. CONCLUSION 10.

REFERENCE
6. 11.
 INTRODUCTION

Every year humans produce nearly 250 million tons of plastic, and much of that plastic ends up in
the environment, harming marine life and other ecosystems. The chemical bonds that makes
plastic so durable makes it equally resistant to natural processes of degradation. Since plastics are
non-biodegradable in nature, it is very difficult to eliminate the waste plastics from nature. Since
1950s 1 billion tons of plastic have been discarded and may persist for hundreds or even
thousands of years. Expenditure incurred on disposal of plastic waste throughout the world as und
USS 2 billion every year. Even for a small country like Honk Kong spends about USS 14 million a
year on the exercise.

The majority of the plastic waste ends up in landfills, and becomes a carbon sink where it may
take up to 1000 years to decompose and potentially leak pollutants into the soil and water. Abu
the plastic wastes are dumped in the oceans threatening the health and safety of marine life. The
uncontrolled incineration of plastic produces polychlorinated dibenzo-p-dioxins, a carcinogen. So,
converting the waste plastic into crude all will have two benefits. First of all, the hazards caused
due to plastic waste can be reduced and secondly, we will be able to obtain some amount of all
from a, which can be further purified to be used as a fuel in different areas such as domestic fuel,
foet for automobiles and industries etc. Thereby, our dependency on fosil fuels will reduce to a
certain extent.

A. Plastics

As a brief introduction to plastics, it can be said that plastics are synthetic organic material
produced by polymerization. They are typically of high molecular mass, and may contain other
substances besides polymers to improve performance and/or reduce costs. These polymers ca be
moulded or extruded into desired shapes

1) There are two main types of plastics thermoplastics and thermosetting polymers
Thermoplastics can repeatedly soften and melt if enough heat is applied and hardened on cooling,
so that they can be made into new plastics products. Examples are polyethylene, polystyrene and
polyvinyl chloride, among others

2) Thermoses or thermosetting can met and take shape only once. They are not suitable for
Repeated heat treatment; therefore, after they have solchfied, they stay sold
 B. Target Waste Plastics

Waste plastics are one of the most promising resources for fuel production because of its high
heat of combustion and due to the increasing availability in local communities. Unlike paper and
wood, plastics do not aboch mach moisture and the water content of plastics is fur lower than the
water content of biomass such as crops and kitchen wastes. The conversion methods of waste
plastics into fuel depend on the types of plastics to be targeted and the properties of other wastes
that might be used in the process. Additionally, the effective conversion requires appropriate
technologies to be selected according to local economic environmental social and technical
characteristics. In general, the conversion of waste plastic into fuel requires feedstock which non-
hazardous and combustible. In particular, each type of waste plastic conversion method has its
own suitable feedstock

The composition of the plastics used as feedstock may be very different and some plastic articles
might contain undesirable substances (eg additives such as flame-retardant containing bromine
and antimony compounds or plastics containing nitrogen, halogens, sulphate or any other
hazardous substances) which pose potential risks I humans and to the environment. The types of
plastics and their composition will condition the conversion process and will determine the pre-
treatment requirements, the combustion temperatures for the conversion and therefore the
energy consumption required, the fuel quality output, the flue gas composition (eg formation of
hazardous flue guise such as Nox and HCI), the fly ash and bonom ash composition, and the
potestul of chemical corrosion of the equipment,

Therefore, the major quality concerns when converting waste plastics into fuel resources are, as
follows:

1)Smooth feeding to conversion equipment. Prior to their conversion into fuel resources. Waste
plastics a subject to various methods of pre-treatment to facilitate the smooth and efficient
treatment during the subsequent conversion process, depending on their structures g rigid, films,
sheets or expanded (family material) the pre-treatment equipment used for each type of plastic
(rushing or shredding) is often different

2) Effective conversion into fuel products: In solid fuel production, thermoplastics act as binders
which form pellets or briquettes by melting and adhering to other non-melting substances such as
paper, wood and thermosetting plastics Although wooden materials are formed ins pellets using a
pelletize, mixing plastics with wood or paper complicates the pellet preparation process Suitable
beating is required to produce pellets from therusplastics and other combustible waste. In liquid
fuel production, thermoplastics containing liquid hydrocarbon can be used as feedstock. The type
of plastic being used determines the processing rate as well as the product yield. Contamination
by undesirable substances and the presence of moisture increases energy consumption and
promotes the formation of by-products in the fuel production process
 CLASSIFICATION OF PLASTICS

Plastics are classified by

their chemical structure of the polymer's hack bone and side chains. Some important groups in
these classifications are the acrylics, polyesters, silicones, polyurethanes, and halogenated plastics
Plastics can also be classified by the chemical process used in their synthesis, such an
condemumon, poly addition, and cross-linking: 2) Law-density polyethylene Low density
polyethylene (LDPE) is used for its toughness, flexibility, and relative transparency, LDPE is used to
make boles that require extra flexibility To take advantage of its strength and toughness, it is used
to produce grocery bags and garbage bags, squeezable bottles, shrink wrap, speech films, and
coating for milk cartons. It can also be found in toys, container lids, and packaging. Polypropylene
(PP) is known for its high meeting point, which makes it ideal for holding hot liquids that cool in
the bottles (for example, katipo and syrup). It can be manufactured to be flexible or rigid. PP is
used to make containers for yogurt, margarita, takeout meals, and dells foods. It is also use for
medicine boules, bottle caps, and some household items
 METHODOLOGY

• Pyrolysis

Pyrolysis is generally defined in the controlled beating of a material in the absence of oxygen. In
plastics Pyrolysis, the macromolecular structures of polymers are broken down into smaller
molecules or oligomers and sometimes monomer units. Further degradation of these subsequent
molecules depends on a number of different conditions including and not limited to) temperature,
residence time, presence of catalysts and other process conditions. The Pyrolysis reaction can be
carried out with or without the presence of catalyst. Accordingly, the reaction will be thermal and
catalytic Pyrolysis. Since majority of plastic used are polyolefin, so extensive research has been
done on this polymer which is vammarized as below, B. Thermal Pyrolysis of Polyolefin The un-
catalytic or dismal Pyrolysis of polyolefin is a high energy, endothelin process requiring
temperatures of at least 350-500 °C

In some studies, high temperature as 700-000 °C is essential in achieving decent product yields.
The extent and the nature of these reaction depend both on the reaction temperature and also on
the residence of the products in the coaction cone, an aspect that is primarily affected by the
reactor design. In addition, actor design also plays a fundamental rule, as it has to overcome
problems related to the low thermal conductivity and high viscosity of the moisten polymers.
Several types of realties have been reported in the literature, the most frequent being fluidized
had reactions, butch reactions and screw kiln reactions. Characteristics of thermal degradation of
Tavy hydrocarbons can be described with the following points

High production of Cpls and C2s in the gas product

Olefins are less branchial.
Some olefins made at high temperature
Gasoline selectivity is poor; Le oil products are a wide distribution of molecular weight.
Gas and coke products are high.
Reactions are slow compared with catalytic reactions.

Thermal Pyrolysis of both virgin and waste plastic as well as other hydro-carbonaceous SOURCES
has been studied extensively in the past. A good member of these thermal cracking studies is on
polyethylene, polypropylene and polystyrene. On the other hand, only a few have worked on the
thermal decomposition of other common plastics such as polyvinylchloride, poly methyl
methacrylate, polyurethane and polyethylene terephthalate. Generally, thermal cracking results in
liquids with low octane value and higher reside contents at moderate temperatures, this art
inefficient process for producing gasoline range fuels. The gaseous products obtained by thermal
Pyrolysis are not suitable for use as fuel products, requiring further refining to be upgraded
useable fuel pedants. A few researchers have sought to improve thermal Pyrolysis of waste
polyolefin without employing the use of catalyst; however, these charges either yielded
insignificant improvements or added another level of complexity and costs to the system.
 Catalytic Cracking of Polyolefin

Addition of catalyst enhances the conversion and fuel quality. As compared to the purely thermal
Pyrolysis, the addition of catalyst in polyolefin Pyrolysis

1) Significantly lowers Pyrolysis temperatures and time. A significant reduction in the degradation
temperature and reaction time Ander catalytic conditions resales in an increase in the conversion
rates for a wide range of polymers at much lower temperatures than with thermal Pyrolysis

2) Narrows and provides better control over the hydrocarbon products distribution

3) Increases the gaseous product yields. Linder similar temperatures and reaction times, much
higher fuscous product yield is observed in the presence of a catalyst for polyethylene.
 MAIN DEVICES USED IN THE PROCESS

A. Condenser It cools the entire heated vapour coming out of the actor. It has an intent and an
outlet for cold water to run through its owner area. This is used for cooling of the vapour. The
gaseous hydrocarbons at a temperature of about 350 C are condensed to about 30-35 C

B. Reactor It is a stainless steel tube of length 300mm, internal diameter 225mm, tar diameter
210mm sealed at one end and an outlet tube at the other end. The reactor is placed under the LPG
burner for extremal heating with the raw material inside. The reactor is made with the following:
stainless steel, mild steel and clay for lagging. The reactor is heated to a temperature of about
450°C and more.

C. Process Description Thermal cracking process without consist was used in converting water
plastic into liquid fuel. Town types of waste plastic are selected for this particular experiment. By
weight 50% of each Low density polyethylene and polypropylene was selected for the experiment.
Both waste plastic am solid hard form. Collected waste plastic was cleaned using quits soup and
water. During waste plastics are cleaned is cerates waste water. This waste water is purified for
reuse using waste water treatment process, washed waste plastics are cut into 1.5 cm size to fit
into the reacted conservatively. For experimental purpose we used 600gm sample 300gm of PP
and 300gm of LDPE A vertical steel actor used for thermal cracking and temperature used ranges
from 100 C to 400 C

When temperature is increased in 270 C Squid slurry turns into vapour and the vapour then
pauses through a condenser unit. At the end we collect liquid fuel. Between 100 C andd250" C
around 20-30% of the fuel is collected and then when raised in 325° C the next 40% is collected
and finally when held at 400° C the yield is fully completed.
During the thermal cracking process pistil portions are not broken down immediately because
plastics have short chain hydrocarbon to long chain hydrocarbon. 1st stage of heat applied breaks
down only the short chain hydrocarbon. When temperature profile is increased the plastic carbon-
carbon hood breakdown slowly. As the temperature is increased the long chains are brown step by
step. During in this thermal cracking process some light gas such as methane, ethane, propane and
butane are produced

D. Catalytic Pyrolysis of plastic Compared with gasification pyrolysis produces les amount of bout
Le between 840 and 1.020 degrees F so it is more energy efficient Through catalytic pyrolysis, a
system was devised to haven’t waste plastics into liquid hydrocarbons, coke and gas which can
then be used as boiler fair for power generation. The technology uses lower temperatures thon
gasification significantly lower, so it's more energy efficient to produce. Through "random de-
polymerization urn selective breaking of carbon-to-carbon hands, in addition to feeding in
proprietary catalytic additives, the resort melts and vaporizes wale plastic in one step at
temperatures between $40 and 1,020 degrees F. On average, 79-80 percent of every pound of
plastic fed into the system is converted to liquid hydrocarbons, coke and gas The resultant coke
can be further processed to produce additional fuel oil. This catalytic pyrolysis system additional
fuel oil. This catalytic pyrolysis system processes polyolefin like polyethylene and polypropylene
with up to 5 percent other plastic

Pyrolytic Conversion Common features of these systems include: Some level of pre-treatment: this
could be as minor as sin reduction or as involved as cleaning and moisture removal. Conversion:
pyrolytic processes are used to cover the plastic to a pus

E. Distillation The gas is converted to liquid form Acid removal process removal of acids that form
in the breakdown of some scrap plastics. These acids require removal because they can be
contriving to the FIF systems as well as the engines that will commune the fuel. Separation refining
final blending the final steps required to make this prestart consumer ready can either be done on
site or in some other plant. The total vocal of fuel oil is 50-65% The problem for this process is the
pyrolysis equipment a corrosion incurred by PVC in mixed plastic wastes. However, the
tempentare caused by pyrolysis is higher and all the reactive time is longer than the other
methods. The octane number of gasoline gained is relatively low and the pour point of diesel oil is
high. More paraffin in produced in the process of pyrolysis. Although this process is simple and
convenient, the converting rate and yield is still lower. The other problem for this process is the
pyrolysis oqisipment's corrosion incurred by PVC in mixed plastic wustes. Therefore, it is strongly
recommended to establish a reasonable sitting system and apply an efficient technique to
eliminate the sonic emissions and highly cursive hydrochlonc acid that is formed. Since the total
yield of the fuel oil with pynlysis is still lower and the quality of all is not satisfied as gasoline and
diesel oil, the upgrade by catalytic cracking for the crude products gained with pyrolysis can be
used .
Stages of Conversion Indirect heating of waste plastics the feedstock would be placed in a
specially designed cartridge. Now the air should be heated with a light industrial burner and re
circulated around the cartridge, transforming the plastic feedstock from a solid to a liquid to a gas
Gasification and movement Using a combination of temperature and vacuum for negative.
presume), the gates are to be pulled from the cartridge mo. a central condensing system.
Condemning gases in oil in the condensing system, the gases are to be cooled and condensed into
cambric crude oil. Waste impugns and then removed from the stream Final transfer and storage of
oil the crude oil product which leaves the condensing system should enter into a coalescing and
settling process and eventually transferred to an exterior storage tank

F. Pyrolysis/Thermal Degradation Pyrolysis is a process of thermal degradation of a material in the

absence of oxygen Plastic is fed into a cylindrical chamber. The pyrolytic gases am condensed in a
specially designed condenser system, to yield a hydrocarbon distillate comprising straight and
branched chain alight, cyclic aliphatic, and acrobatic hydrocarbons, and liquid is separated wing
fractional distillation to produce the liquid fuel products.

The plastic is pyrolysis at 370°C-420°C.

(1) Evenly beating the plastic to a narrow temperature range without exceling temperature
Variations

(2) Purging oxygen from pyrolysis chamber,

(3) Managing the carbonaceous char by-product before it acts as a thermal insulator and lowers
the heat transfer to the plastic.

(4) Careful condensation and fractionation of the pyrolysis vapours' to produce distillate of good
quality and consistency

ADVANTAGES OF PYROLYSIS PROCESS

(a) Volume of the waste is significantly reduced (<50-90%),

(b) Solid, liquid, and gaseous fuel can be produced from the waste,

(c) estimable transportable fuel or chemical feed shock is obtained.

(d) Environmental problem is reduced.

(e) Desirable process as energy is obtained from renewable sources like municipal solid waste or
sewage sludge.
 CONCLUSION

Plastics present a major threat to today's society and environment. Over 14 million tons of plastics
urea dumped into the ocean annually, killing about 1,000,000 species of oceanic life. Though
mankind has awoken to this threat and responded with developments in creating degradable bio-
plastics, there is still no conclusive felon done repair the damage already caused. In this regard,
the catalytic Pyrolysis studied here presents an efficient, clean and very effective means of
removing the debris that we have left behind over the last several decades. By converting plastics
in fuel, we salve two ices, one of the large plastic seas, and the other of the feel shortage. This dual
benefit, though will exist only as long as the waste plastics last, but will surely provide a strong
platform for us to build on a sustainable, clean and green faun. By taking into account the financial
benefits of such a project, it would be a great book to our economy. So from the studies
conducted we can conclude that the properties of the fuel obtained from plastics are similar to
that of petrol and further studies on this field can yield better results
 REFERENCE

https://www.research gate.net/publication/337309474

https://bioscience.ion.org/article/10.1088/1742-6596/1362/1/012103/meta

https://www.dip.com/2073-4360/13/6/915/pdf