Design and Development of Pyrolysis plant for plastic waste using catalyst.

Techs: Software: Using Solid works and Ansys workbench for 3d modeling & Simulations. Hardware: For the outer body the cylinder CNC laser cutting, arc welding, gas welding and drilling used. ?
Department: Mechanical Engineering
MS Team URL: URL not found

Our project focuses on the design and development of a plastic pyrolysis plant that aims to convert waste plastic into valuable products such as fuel oil, gas, and char. A key feature of our project is the use of catalysts—specifically magnesium oxide (MgO), zinc oxide (ZnO), and aluminum oxide (Al2O3)—to enhance the efficiency and selectivity of the pyrolysis process. These catalysts help reduce the reaction temperature, improve fuel yield, and increase the overall economic viability of the process.The plant design includes essential components such as a feedstock chamber, reactor, condenser, gas collection unit, and residue collection system. This project not only contributes to sustainable waste management but also promotes the concept of a circular economy by converting non-recyclable plastic into usable energy sources. It integrates principles from thermodynamics, chemical engineering, and mechanical design, providing a multidisciplinary learning experience.

Objectives

To design and fabricate a small-scale pyrolysis plant for converting plastic waste into fuel. To utilize and compare the performance of catalysts (MgO, ZnO, and Al2O3) in the pyrolysis process. To reduce the environmental impact of plastic waste through thermal degradation. To evaluate the fuel yield, quality, and efficiency of the process with different catalysts. To promote sustainable waste management and alternative energy generation. To apply principles of thermodynamics, chemical reactions, and mechanical design in a practical engineering project. To demonstrate the technical and economic feasibility of catalytic pyrolysis at a small scale.

Socio-Economic Benefit

Reduction in Plastic Pollution: Helps clean the environment by converting non-recyclable plastic waste into useful products. Alternative Fuel Source: Produces low-cost fuel that can reduce dependency on imported fossil fuels. Job Creation: Promotes employment opportunities in waste collection, plant operation, and fuel distribution. Economic Uplift of Informal Sector: Supports local waste pickers and recyclers by adding value to collected plastic. Energy Access for Rural Areas: Provides a decentralized energy solution for communities with limited energy access. Cost-Effective Waste Management: Offers a sustainable and affordable method for municipalities to manage plastic waste. Encouragement of Green Entrepreneurship: Opens avenues for small-scale businesses in renewable energy and recycling sectors. Health Improvements: Reduces risks related to open burning and dumping of plastic waste, leading to cleaner surroundings and better public health.

Methodologies

Methodology: The methodology of this project involves a systematic approach combining design, experimentation, and analysis to develop a functional plastic pyrolysis plant. The process can be divided into several key stages: material collection, plant design, catalyst selection, experimental setup, pyrolysis reaction, and product analysis. 1. Plastic Waste Collection and Preparation: The first step involves collecting different types of plastic waste, primarily polyethylene (PE), polypropylene (PP), and polystyrene (PS), which are common in household and industrial waste streams. These plastics are sorted, cleaned to remove contaminants, and shredded into small uniform pieces (typically 1–2 cm) to ensure consistent thermal decomposition during pyrolysis. 2. Design and Fabrication of Pyrolysis Plant: A batch-type pyrolysis reactor was designed using basic principles of heat transfer, material strength, and thermal insulation. The main components include: A reactor chamber made of stainless steel for withstanding high temperatures. A heating system (electric or gas burner) to supply controlled heat to the reactor. A condenser unit for cooling and collecting pyrolysis vapors into liquid fuel. A gas collection chamber to separate non-condensable gases. A char collection unit for solid residues. The system is thermally insulated to minimize heat loss, and temperature sensors are installed to monitor the reaction. 3. Catalyst Selection and Preparation: Three catalysts—magnesium oxide (MgO), zinc oxide (ZnO), and aluminum oxide (Al2O3)—are selected based on their known catalytic activity, thermal stability, and cost-effectiveness. These catalysts are ground to a fine powder and mixed with the plastic feedstock at different ratios (e.g., 5–10% by weight) before being fed into the reactor. Each catalyst is tested separately in different batches for performance comparison. 4. Pyrolysis Process: The reactor is sealed and heated in the absence of oxygen to initiate the pyrolysis reaction. The temperature is gradually increased to around 400–500°C, depending on the type of plastic and catalyst used. As the plastic decomposes, vapors are produced and passed through the condenser. The condensed vapors are collected as pyrolysis oil, while non-condensable gases are captured and, if sufficient, recycled as fuel for heating. The remaining char is collected at the bottom of the reactor. Each batch is run under controlled conditions to ensure safety and repeatability. Multiple experiments are conducted with each catalyst to determine the optimal operating temperature, reaction time, and catalyst-to-plastic ratio. 5. Product Analysis: The pyrolysis oil is analyzed for its physical and chemical properties, including density, viscosity, calorific value, and composition (via gas chromatography). The effectiveness of each catalyst is evaluated based on: Oil yield (%), Reaction time Energy efficiency.

Outcome

This project involves the design and development of a small-scale plastic pyrolysis plant to convert waste plastic into useful fuel products. The pyrolysis process thermally decomposes plastic in the absence of oxygen, producing fuel oil, gas, and char. To enhance the efficiency and fuel yield, the project incorporates catalysts such as magnesium oxide (MgO), zinc oxide (ZnO), and aluminum oxide (Al2O3). The plant is designed for batch operation and includes components like a reactor, condenser, and gas collection unit. The project aims to offer an eco-friendly, cost effective solution to plastic waste management while contributing to alternative energy production. It also provides valuable insights into sustainable engineering practices.

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