MATTU UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

Group -2

NAME ID

1. SELAMAWIT GIRMA 4149

2. IFTIYOOM KEJELA 3781
3. LIKE TAKELE 2697
4. YIMER MOHAMMED 5601

Submission: December, 29, 2024

Contents
CHAPTER ONE..............................................................................................................................1

1. Introduction..................................................................................................................................1

1.1. Background...........................................................................................................................1

1.2. Objective...............................................................................................................................3

1.2.1. General Objective..........................................................................................................3

1.2.2. Specific Objectives........................................................................................................3

1.3. Statement of the Problem......................................................................................................3

1.5. Significance of the project....................................................................................................4

CHAPTER TWO.............................................................................................................................5

2. Literature Review........................................................................................................................5

2.1 Product Assessment...............................................................................................................5

2.1.1 Introduction.....................................................................................................................5

2.1.2. Bio Fuel Demand of the World.....................................................................................5

2.1.3. Bio fuel Demand of Ethiopia.........................................................................................6

2.2. Source of raw material..........................................................................................................7

2.2.1. Municipal Plastic Waste................................................................................................7

2.2.2. Industrial Plastic Wastes................................................................................................7

2.2.3. Factor Affecting Raw Material Selection......................................................................8

2.3. Detail Process Description of Waste Plastic Conversion into Liquid Fuel........................10

2.4. Application of Diesel Fuel..................................................................................................11

CHAPTER THREE.......................................................................................................................13

3. Process Description and General flow sheet.............................................................................13

3.1 Flow diagram of conversion of waste plastic into liquid fuel.............................................13

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 3.2 General flow sheet for conversion of waste plastic into liquid fuel....................................14

CHAPTER FOUR.........................................................................................................................15

4. Materials and Methods..............................................................................................................15

4.1. Materials.............................................................................................................................15

4.1.1 Raw Materials Used (Inputs)........................................................................................15

4.1.2 Main devices used in the process..................................................................................15

4.2. Experimental Procedure......................................................................................................15

CHAPTER FIVE...........................................................................................................................17

5. Material and Energy Balance.....................................................................................................17

5.1 Material Balances................................................................................................................17

5.1.1. Mass Balance on Reactor.............................................................................................17

5.1.2. Mass Balance on Shredder...........................................................................................19

5.2 Energy balance.....................................................................................................................19

5.2.1 Amount of Energy Used on Reactor Furnace System..................................................19

5.2.2 Energy balance on condenser.......................................................................................20

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 CHAPTER ONE

1. Introduction

Plastics are integral to our daily lives due to their unique properties, including toughness,
lightweight, water and chemical resistance, thermal stability, low electrical and thermal
conductivity, ease of fabrication, a wide range of colors, design flexibility, durability, and energy
efficiency. These attributes make plastics ideal for various applications, such as packaging,
agriculture, construction, insulation, automotive, electronics, textiles, sports equipment, and toys.
Effective disposal methods for municipal and industrial plastic waste include landfilling,
incineration (for energy recovery), true material recycling (producing similar recycled products
or recovering monomers), and chemical recovery. Addressing the appropriate treatment of
plastic waste is crucial for waste management, considering energetic, environmental, economic,
and political factors.
The pyrolysis process has emerged as a viable waste-to-energy technology, converting plastic
waste into bio-fuel as a substitute for fossil fuels. One of its main advantages is its ability to
process unsorted and dirty plastics, with minimal pretreatment required—primarily sorting and
drying. Unlike incineration, pyrolysis does not emit toxic or environmentally harmful substances.
However, challenges remain in designing cracking reactors due to plastics’ low thermal
conductivity and high viscosity. Many researchers utilize batch or semi-batch reactors for their
straightforward design and operational simplicity. Catalytic degradation offers a solution to these
challenges, as catalysts can lower reaction temperatures, enhance decomposition rates, and
improve product quality and residence time.
Incinerating waste plastics directly contributes to increased greenhouse gas emissions,
particularly carbon dioxide (CO2) and particulate matter. Current regulations and rising
ecological awareness make landfilling a less viable option due to legal constraints and high costs.
Additionally, there is a growing requirement for diesel to be sulfur-free.

1.1. Background

Plastic, a high molecular weight material, was first developed by Alexander Parkes in 1862. It is
primarily composed of polymers, which are molecules formed by repeating simple units. Plastics
are a broad category of synthetic or natural materials made up of high-molecular chains,

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predominantly consisting of carbon. In everyday language, the terms plastics, polymers, and
resins are often used interchangeably. A plastic material is defined as a substance that contains
combinations of carbon with other elements like oxygen, hydrogen, nitrogen, and more, which
can be made liquid during manufacturing and shaped using heat and pressure.
Plastics are lightweight, durable, and versatile, making them suitable for a wide range of
applications. However, due to the fossil fuel crisis over the past decade, there has been a
significant push towards developing alternative energy sources such as biomass, hydropower,
geothermal, wind, solar, and nuclear energy. Research in to alternative fuel technologies aims to
provide substitutes for fossil fuels.
The global consumption of plastic continues to grow daily, leading to an increase in plastic
waste. Between 2009 and 2010, global plastic production rose by 15 million tons (6%) to reach
265 million tons, reflecting a long-term growth trend of nearly 5% per year over the last two
decades. In 2010, Europe produced 57 million tons (21.5%) of this total, while China became the
leading production region at 23.5%.
As the population increases, the demand for plastic products has steadily risen over the past 40
years. Since plastics are non-biodegradable, they do not easily reintegrate into the natural carbon
cycle, resulting in their life cycle concluding at waste disposal sites. In many developed nations,
domestic organic waste, including plastic packaging, is typically managed through sanitary land
filling or incineration. In the early 2000s, approximately 65–70% of plastic waste was land filled,
while 20–25% was incinerated, with only about 10% being recycled.
In Japan, during the early 1980s, about 45% of municipal plastic waste was land filled and 50%
incinerated, with the remaining 5% recycled. In the USA, over 15% of total municipal solid
waste (MSW) was incinerated in 1990, but only around 1% of post-consumer plastics were
recycled. Meanwhile, India achieved a significant recycling milestone in 1998, recycling around
800,000 tons, which represented 60% of its plastic waste, involving 2000 recycling units—the
highest recycling rate globally.
By 2006, Europe reached a notable point where the recovery and disposal rates of used plastic
were equal, with the recovery rate for post-consumer plastics at 50% and a recycling rate of
19.7%, up from 18% in 2005. Energy recovery also increased to 30.3%, reflecting stricter
landfill regulations in several countries. Of the 11.5 million tons recovered, 4.5 million tons were
recycled into materials and feedstock, while 7.0 million tons were utilized for energy recovery.

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In Ethiopia, like many developing countries, plastic consumption has surged due to economic
growth and rapid urbanization. Overall, recent data indicate that recycling operations, both
material and energy recovery, are on the rise compared to land filling, driven by stricter
regulations and increased public awareness

1.2. Objective

1.2.1. General Objective

 To Design a plant for the production of 500,000 kg/day of diesel fuel from waste
plastics
1.2.2. Specific Objectives
 Conduct an energy and material balance.
 Design and construct a pyrolysis unit for producing liquid fuel from plastic waste.
 Carry out equipment sizing.
 Estimate costs and perform a profitability analysis.
 Choose a suitable site and develop a plant layout.
 Compare the properties of the resulting liquid fuel with those of diesel fuel.

1.3. Statement of the Problem

Plastics are non-biodegradable materials, taking approximately 300 to 500 years to decompose.
Improper management of plastics leads to several environmental issues, including:
1. Littered plastics detract from the aesthetic appeal of cities, clogging drains and polluting
public spaces.
2. Burning plastic waste can result in air pollution due to the release of harmful gases.
3. The accumulation of household plastic waste poses environmental hazards.
4. There is a potential fuel shortage in the country, which could be alleviated by converting
waste plastics into diesel.
This project aims to tackle these issues by recycling plastic waste into liquid fuel.
1.4. Scope of the project
The project will be located in Mettu town. Mettu town is found in west Illuababor zone of
Ethiopia. It is located about the 605 km south west from Addis Ababa, with an emphasis on
recycling waste plastic into liquid fuel through the pyrolysis process. The benefits of this project
will primarily impact Mettu town, but its applications could extend throughout Ethiopia. Users of

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liquid fuel often seek petroleum alternatives like gasoline, diesel, and heavy oil. These fuels
typically include various additives mixed with the liquid hydrocarbons to enhance burner and
engine performance.

1.5. Significance of the project

The primary goal of this project is to produce liquid fuel from waste plastics, aiming to keep
Mettu town clean and prevent the accumulation of plastic waste in Mettu town. additionally, the
project will create job opportunities for both educated and uneducated youth. Ultimately, the
produced fuel will be used for domestic purposes as well as in vehicles and industries after
further refinement. This initiative seeks to reduce dependence on Gulf countries for fossil fuels,
thereby contributing to the country’s economic growth.

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 CHAPTER TWO

2. Literature Review

2.1 Product Assessment

2.1.1 Introduction
To conduct a thorough background study on the technologies for converting waste plastics into
liquid fuel, a literature survey was performed to explore various methods used globally. The
findings indicate that plastic waste can be transformed into crude oil, which can then be distilled
into various products such as petrol, diesel, and kerosene. This process is capable of converting
all HDPE waste plastics into different grades of liquid fuels, particularly jet fuel. Liquid fuel
refers to plastic-derived hydrocarbons at normal temperature and pressure, and only certain types
of thermoplastics can undergo thermal decomposition to produce liquid hydrocarbons suitable
for fuel.
The fuel obtained through pyrolysis exhibits properties very similar to those of diesel fuel.
"Diesel fuel" is a broad term that encompasses any fuel used in compression ignition engines,
and plastic-derived oil can serve as an alternative fuel. However, it commonly refers to fuels
specifically created for diesel-powered vehicles.
After reviewing various sources, it is clear that different pyrolysis processes have been utilized to
effectively convert plastic waste into fuels. Before delving into these processes, it is essential to
define what plastics are.
Plastics are synthetic organic materials created through polymerization. They generally possess
high molecular mass and may include additional substances to enhance performance or reduce
costs. Many everyday materials are made from plastics, which consist of polymers—large
molecules formed by repeating units known as monomers. Most plastics have between 500 and
20,000 or more repeating units. Plastics are produced by chemically bonding monomers in a
process called polymerization. For example, polyethylene, commonly used in grocery bags and
packaging, is formed by linking ethylene (C₂H₄) molecules. Most plastics are derived from
crude oil, where chemical reactions transform the molecules into monomers, which are then
assembled into polymers that can be processed into plastics.

2.1.2. Bio Fuel Demand of the World

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Currently, approximately 129 million tons of plastics are generated globally each year, with 60%
(about 77 million tons) derived from petroleum. If this plastic were recycled, it could yield
around 69 million tons of oil, enough to fill 350 tankers. In Japan, recycling has become
mandatory due to laws enacted in April 1997 regarding civil receptacle materials and the
compulsory recycling of waste plastics starting in 2000. Consequently, polystyrene containers
from supermarkets and other sources are collected and processed in towers at temperatures
between 400-500°C to convert them into fuel oil.
This high-temperature processing creates challenging working conditions for engineering teams,
as engine rooms can reach temperatures of around 45-50°C. Additionally, because of the extreme
heat (about 80-100°C), some fine components of the fuel may degrade or coke, as noted by Jerzy
Walendziewski. Experiments using waste plastic oil in engines have demonstrated stable
performance, which can significantly reduce fuel heating costs. Moreover, this process also
lowers the emission of soluble organic fractions (SOF). This study aims to explore new
applications for waste plastic oil.
2.1.3. Bio fuel Demand of Ethiopia
A survey conducted by the Central Statistics Agency (CSA) in 2005 revealed that approximately
71.1% of households in Ethiopia rely on kerosene for lighting, followed by firewood (15.7%)
and electricity (12.9%). Urban residents predominantly use electricity (75.3%), while kerosene
(80.1%) and firewood (18.5%) are more common in rural areas.
About 95% of Ethiopia's total energy consumption comes from traditional biomass fuels, with
only 5% sourced from modern energy options. The biomass primarily consists of firewood,
charcoal, dung, and crop residues, which depend heavily on local forest resources and
agricultural byproducts. This reliance has led to significant degradation and loss of the country's
forest and land resources, resulting in desertification, decreased agricultural productivity, and
recurring droughts. Additionally, there has been an increase in greenhouse gas emissions.
Ethiopia currently imports all its petroleum fuel needs, spending over 80% of its foreign earnings
annually. The demand for petroleum fuels is rising rapidly due to economic growth and
expanding infrastructure. Therefore, it is crucial to seek alternative energy sources to address
economic, environmental, and social challenges.
Bio fuels are becoming a key driver worldwide, with local availability of bio fuel feedstocks
offering significant benefits for rural communities in terms of job creation and improved living

6
standards. They also represent a viable alternative energy source for a wide range of thermal
applications. Consequently, the development of bio fuels is a critical component of energy
strategy, promoting renewable energy and efficiency.
In light of this information, our product—liquid fuel derived from waste plastics—offers a
solution to both energy and environmental issues.

2.2. Source of raw material

Waste plastics represent a highly promising resource for fuel production due to their high heat of
combustion and their growing availability within local communities. Unlike paper and wood,
plastics have low moisture absorption, resulting in significantly lower water content compared to
biomass sources like crops and kitchen waste. Plastic waste can be categorized into two main
types: municipal waste and industrial waste.
2.2.1. Municipal Plastic Waste
Municipal plastic waste (MPW) is typically part of municipal solid waste, as it consists of
discarded items collected from households. Sources of MPW include a variety of domestic
products such as food containers, milk lids, water bottles, packaging foam, disposable cups,
plates, cutlery, CD and cassette cases, fridge liners, vending cups, electronic equipment cases,
drainage pipes, carbonated drink bottles, plumbing pipes, guttering, flooring materials,
cushioning foams, thermal insulation foams, and surface coatings. Agricultural sources also
contribute to MPW, including mulch films, feed bags, fertilizer bags, and temporary tarpaulins
used for covering hay or silage. Additionally, MPW can include plastic waste from wire and
cable production and automobile wrecking. Consequently, the collected MPW consists mainly of
plastics like polyethylene, polypropylene, polystyrene, polyvinyl chloride, and polyethylene
terephthalate. The proportion of plastics in MPW has seen a significant increase.
2.2.2. Industrial Plastic Wastes
Industrial plastic waste consists of materials generated by large-scale plastics manufacturing,
processing, and packaging industries. This type of waste primarily comes from sectors such as
construction and demolition (e.g., polyvinyl chloride pipes and fittings, tiles, and sheets),
electrical and electronics industries (e.g., switch boxes, cable sheaths, cassette cases, TV
screens), and the automotive industry (e.g., spare parts like fan blades, seat coverings, battery
containers, and front grills). Industrial plastic waste typically has favorable physical

7
characteristics; it is generally clean, free from contamination, and available in substantial
quantities.
To effectively convert waste plastics into fuel, a comprehensive literature survey was conducted
to explore various technologies applied globally. These methods can yield products such as
petrol, diesel, and kerosene through distillation processes. Specifically, HDPE waste plastics can
be converted into different grades of fuel, including jet fuel. The literature reveals that various
forms of pyrolysis processes have been successfully utilized to convert plastic waste into
efficient fuels.
For instance, a company in Scotland is actively extracting diesel and kerosene from plastic
without harming the environment. Several other European countries are also working on similar
initiatives to convert plastic waste into useful fuels. Additionally, this process has the potential to
generate some electricity, further contributing to waste management efforts.
The primary goal of state organizations is to enhance the welfare of the population while
generating profits akin to private companies. To establish such plants, the following inputs are
essential:
1. Daily data collection on plastic waste from local bodies throughout the state.
2. A feasibility study to assess land requirements, construction costs, and manpower needs.
3. Identifying suitable locations for plant allocation and obtaining permissions from
government agencies, such as the Pollution Control Board.

2.2.3. Factor Affecting Raw Material Selection

In general, converting waste plastic into fuel requires feedstocks that are non-hazardous and
combustible. The composition of the plastics used can vary significantly, and some plastic items
may contain undesirable substances, such as additives like flame retardants that include bromine
and antimony compounds or plastics that contain hazardous elements like nitrogen, halogens, or
sulfur. These substances can pose risks to both human health and the environment.
The types of plastics and their specific compositions will influence the conversion process,
determining the necessary pretreatment steps, combustion temperatures, energy consumption,
fuel quality, flue gas composition (including potentially harmful gases such as NOx and HCl),
and the makeup of fly ash and bottom ash. Additionally, they can affect the likelihood of
chemical corrosion in processing equipment.

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Common Plastics for Recycling
Not all plastics can be recycled. The four types of plastics most commonly recycled include:
 Polyethylene (PE) - both high-density and low-density variations
 Polypropylene (PP)
 Polystyrene (PS)
 Polyvinyl chloride (PVC)
A common challenge in recycling is that many plastics are composed of multiple types of
polymers or include fibers (composites) for added strength, making it difficult to identify and
recover them. However, there are several simple tests available to differentiate between the
common types of polymers, facilitating their separation for processing.

Table 2.1 method of identifying types of plastic [12]

Test PE PP PS PVC

Water floats Floats sinks sinks

Burning Blue flame with Yellow flam Yellow sooty Yellow sooty
yellow with blue phase drops smoke does not
continue to burn
its flame
removed.
Smellafter Like candle wax Likecandle Sweet Hydrochloric
burning waxless acid
strong than
PE

Scratch Yes No No No

Table 2.2 types of waste plastic and recyclability [13]

Mark type recyclabl abbreviation Description and common use

9
 e
1 yes PET Poly ethylene terephthalate
beverage.
2 yes HD PE High-density polyethylene milk
detergent oil bottles, toys
containers used outside part and
plastic bags.
3 Yes but not PVC Vinyl/polyvinyl chloride food
common warp vegetable oil bottle blister
package or automotive parts.
4 yes LDPE Low density poly ethylene many
plastic bags shrink-warp garment
bags or containers.
5 yes PP Polypropylene. Refrigerated
container most bottle tops some
carpet and some food warp
6 Yes but not PS Through away utensil meat
common package protective package
7 some …………… Others usually layered or mixed
plastic

Recycling is a strategy aimed at preventing the buildup of excessive waste by reprocessing

materials for use in the production of new items. Today, it is widely recognized as a key
approach to environmental protection. Plastic waste can be transformed into valuable gas and
liquid fuels through various chemical recycling methods, including hydrogenation, chemical de
polymerization, gasification, thermal cracking, and catalytic conversion.

2.3. Detail Process Description of Waste Plastic Conversion into Liquid Fuel

The method for converting plastics into liquid fuel involves pyrolysis and the condensation of the
resulting hydrocarbons. Pyrolysis is the thermal breakdown of materials in an inert environment,
such as nitrogen. During the production of liquid fuel, suitable plastics are placed in a reactor

10
where they decompose at temperatures between 450°C and 550°C. Once the plastics have
sufficiently decomposed to evaporate, the resulting oil—composed of liquid hydrocarbons—is
continuously distilled.

The evaporated oil undergoes further cracking with a catalyst. The boiling point of the produced
oil is managed through the operational conditions of the reactor, cracker, and condenser. In some
cases, fractional distillation equipment is used to refine the product to meet specific user needs.

After distillation, hydrocarbons with higher boiling points, such as diesel, kerosene, and
gasoline, are condensed using a water-cooled condenser and collected in a storage tank via a
receiver tank. Gaseous hydrocarbons like methane, ethane, propylene, and butanes cannot be
condensed and are incinerated in a flare stack, which is necessary when the exhaust gas volume
from the reactor is anticipated to be large.

Fig 2.1 process flow diagram of waste plastic recycling into liquid fuel

2.4. Application of Diesel Fuel

Diesel fuel is essential for keeping the global economy active. It supports the transportation of
consumer goods worldwide, powers electricity generation, and enhances agricultural efficiency,

11
all of which contribute to improved living standards. The main applications of diesel fuel
include:

 On-road transportation
 Off-road activities (such as mining, construction, and logging)
 Agriculture
 Rail transport
 Electric power generation
 Military logistics
 Marine shipping

CHAPTER THREE

3. Process Description and General flow sheet

12
3.1 Flow diagram of conversion of waste plastic into liquid fuel

Collectionand shredding of household waste plastic

Feeding in to the reactor

Heating of waste plastic in the presence of catalyst

Movement ofliquid vapor into condenser

Collection of liquid fuel

Purification of liquid fuel

Fig 3.1 flow diagram of waste plastic into liquid fuel

1. Collection and Shredding of Household Waste Plastics
Collecting waste plastics is relatively straightforward compared to other types of waste. Plastics
are widely available in large quantities from households, roadsides, hospitals, hotels, and more.
Once collected, the plastics are shredded to reduce their size. The types of plastics typically
involved include:

 Polyethylene (PE)
 Polypropylene (PP)
 High-density polyethylene (HDPE)
 Low-density polyethylene (LDPE)

2. Heating of Plastic in the Presence of Catalyst

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This step involves a thermo-chemical process for converting plastic waste by heating the
feedstock at high temperatures in the absence of air, producing gaseous products. A catalyst is
used to lower the operating temperature during this process.
3. Condensation of Gas to Obtain Raw Fuel
After heating the waste plastic to temperatures between 300°C and 500°C in the pyrolyzer, the
gas produced is directed through an outlet submerged in a water-filled jar to condense the vapors
and obtain raw fuel, which floats on the surface. This condensed liquid is then extracted through
a designated outlet. Optionally, the liquid can be further separated using a separator.

3.2 General flow sheet for conversion of waste plastic into liquid fuel

Fig3.2 general flow sheet of waste plastic conversion in to liquid fuel

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 CHAPTER FOUR

4. Materials and Methods

4.1. Materials

4.1.1 Raw Materials Used (Inputs)

Plastic waste is gathered from hotels, hospitals, industries, and various environments such as
roads, schools, and universities before processing. This collection aims to minimize voids within
the reactor and maximize the amount of plastic waste loaded into it.

Municipal plastic waste (MPW) is typically part of municipal solid waste, discarded alongside
household plastics. Sources of MPW include domestic items like food containers, milk caps,
water bottles, packaging foam, disposable cups, plates, cutlery, and cases for CDs and cassettes.
Additionally, it includes fridge liners, vending cups, electronic equipment casings, drainage
pipes, carbonated drink bottles, plumbing pipes, guttering, and flooring materials.

4.1.2 Main devices used in the process

A. Condenser
The condenser cools the heated vapor exiting the reactor. It features an inlet and outlet for cold
water to circulate around its exterior, facilitating the cooling process. The gaseous hydrocarbons,
initially at around 350°C, are condensed to approximately 30–35°C.
B. Reactor
The reactor is a stainless-steel tube sealed at one end, with an outlet tube at the other. It is
positioned under an LPG burner for external heating while containing the raw materials. The
reactor is constructed from stainless steel, mild steel, and clay for insulation. It is heated to
temperatures of around 450°C and above.

4.2. Experimental Procedure

The system consists of a reactor-furnace setup, where the furnace temperature is kept constant
using a PID controller. A condenser is attached to the outlet of the reactor to condense the vapors
produced. The condensed liquid is collected in a jar at the end of the condenser. Plastic shreds
are loaded into a 300 ml reactor, which is then placed in the furnace for heating at a temperature

15
that maximizes liquid product yield. As the reaction occurs, vapors exit the reactor through a
designated outlet and are condensed in the condenser. Water circulates through the condenser as
a cooling medium via a pump. The condensed vapors are collected as the liquid product, while
some non-condensable gases are released. The collected liquid consists of oily water and liquid
oil, with the oily water containing dissolved hydrocarbons. These two components are separated
based on their density.

The steps involved in the process are as follows:

1. Feeding: Feedstocks are introduced into the reactor via a feeder, and the inlet is closed.
2. Heating: The reactor's temperature is increased using a heating source, which heats the
contents inside.
3. Condensing: At high temperatures, the plastic evaporates, and the vapor is condensed to
atmospheric temperature using straight and spiral tube condensers.
4. Liquid Collection: The product exiting the condenser is collected in a liquid collector. A
cyclone separator is included at the end of the condenser to separate the liquid plastic fuel
from non-condensable gases, which are reused to heat the pyrolysis unit.
5. Water Wash, Purification, and pH Test: This step involves several purification
processes. Equal parts of plastic fuel and water are mixed in a container and shaken well,
then left to settle for 5-7 hours. The water and some crystals settle at the bottom, while
the pure plastic fuel remains on top.
6. Purification: The plastic fuel is further purified using filter papers and filters.
7. pH Test: After purification, the pH value of the plastic fuel is measured with a pH meter.
If the pH is below 7, indicating acidity, the fuel must be washed multiple times with
water to raise the pH to 7.

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 CHAPTER FIVE

5. Material and Energy Balance

5.1 Material Balances

A material balance taken over the complete process will determine the quantities of raw
materials required and products produced. Balances over individual process units set the process
stream flows and compositions.
The law of conservation of mass states that mass can be neither created nor destroyed. Material
balances are the basis of process design.

Fig 5.1 block diagram of liquid fuel production from waste plastic
5.1.1. Mass Balance on Reactor
Assumption
• 90%conversion
• Amount of catalyst used=0.5kg/1000kg raw plastic
• steady state

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 Accumulation=mass input-output +generation from reaction
Accumulation = 0 and generation =0
Production Target
 Diesel Fuel Production: 500,000 kg/day
Conversion Efficiency
 Diesel yield from waste plastics: 90%
 By-product’s yield: 10% (gases, char, etc.).
Mass Balance Calculation
Input Mass
To find the total input mass of waste plastics required:
Diesel output 500 , 000 kg
Feedstock required= = ≈ 555 ,556 kg/day
Diesel yield 0 . 90
Mass Balance across the Reactor
Shredded plastic X kg/day By -
products
Reactor
Catalyst 0.5kg/1000Kg of plastic X kg/day Diesel
Fuel

1. Input to Reactor:
o Total feedstock (plastic waste): 555,556 kg/day
2. Outputs from Reactor:
o Diesel Fuel (Output): 500,000 kg/day
o By-products:
By-products = Total feedstock − Diesel output
By-products=555,556 kg/day−500,000 kg/day≈55,556 kg/day
Mass Balance Equation:
The mass balance around the reactor can be formulated as:
Input = Output (Diesel) + Output (By-products)

555,556 kg/day = 500,000 kg/day + 55,556 kg/day

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Catalyst Requirement Calculation
Given the catalyst usage rate:
 Catalyst used: 0.5 kg per 1000 kg of raw plastic.
Calculating the total catalyst required for the feedst
Diesel output 500 , 000 kg
F eedstock required= = ≈ 555 ,556 kg /day
Diesel yield 0 . 90

catalyst required= ( 1000 kg )

0.5 kg
× Feedstock required

catalyst required= ( 1000 kg )

0.5 kg
×555,556 kg ≈277.78 kg/day

5.1.2. Mass Balance on Shredder

Raw plastic shredder shredded plastic

Assumptions
• The system is at Steady state

• There is no reaction

Accumulation=input-output+ generation-consumption
Since accumulation generation and consumption terms are =0
The simplified mass balance is as follows
Input=output
So, 555,556 kg/day shredded plastic use 555,556 kg/day of raw plastic

5.2 Energy balance

5.2.1 Amount of Energy Used on Reactor Furnace System

Pyrolysis takes place in isothermal CSTR which operates at 475 by the heat source from furnace.
External heat source is that supplied by electrical heating. Thus, for the sake of convenience, we
are going to do the energy required to breakdown the given plastic from the furnace.
The heat Q =energy from the furnace to the reactor the temperature of the feed stream is 25 and
the temperature in the Reactor is 475 which is constant. p of polypropylene=0.5 J/Kg

19
Assumptions
• Kinetic and potential energy negligible compared to the heat added =0
• There is no shaft work and the flow of shredded plastic into the reactor is due to gravitational
energy.
• The type of feed is polypropylene plastic
Q
Raw plastic non-condensable vapor
Reactor

Fuel gas

U + EK + EP=Q+W
But U= (H-PV) = H- (PV),
since the pressure and the volume of the reactors are constant the (PV) terms=0
From thermodynamics H= mc p ∆T
So Q= m cp T= 555,556 kg/day *1920 J/Kg *(475 -25 ) = 4800.0038/day of energy is required in
order to pyrolysis the shredded plastic.
Since the specific heat capacities of different types of plastics are different so we need variable
heat for different feed.
5.2.2 Energy balance on condenser

Non-condensable vapor Fuel gas

Condenser Liquid fuel

As the operating temperature of the reactor and furnace system is 475°C so we assume
temperature of the vapors coming out of the reactor to be at around 420°C.
Now, (Vapors from Reactor) = (Fuel Gas) + (Liquid-Fuel))

So, input for condenser = 555,556Kg/day=385.803kg/s of vapors which comprises of 0.01Kg

of Non condensable (Fuel Gas) and 0.09kg/s of condensable liquid product. Here a very rough
estimation has to be done in order to determine energy recovered while condensing. Here, the
process is condensation of mixture of hydrocarbon vapors. In order to evaluate the energy
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recovered during condensation and design the condenser mole fraction of each component of
hydrocarbon vapor mixture is required with their specific heat capacity, thermal conductivity,
viscosity, heat of vaporization, etc. which are not available. So, in this estimation, the
hydrocarbon vapor mixture is considered as a single component hydrocarbon vapor with
specific heat of vapor as 0.5 KJ/Kg K since it varies in the range of 0.5-3 KJ/Kg K for
hydrocarbon vapors at constant pressure.
Specific heat of liquids can be obtained using Kopp,s rule from its chemical composition, i.e.
C, H, N, S and O composition. As the data is not furnished due to unavailability of equipment
so average values for C, H, N, S and O composition is taken from the literature as the
properties of our liquid-fuel lies considerably in the range of other similar products. Thus, C =
86.78; H =
12.61; N = 0.5; S = 0.072; O = 0.038

From Kopp’s rule, Specific Heat = 1.75 KJ/Kg K.

Distillation rang for liquid oil
Initial Boiling point= 70°C
Final Boiling Point =384°C
Now,
(Total Energy Recovered)= (Energy by Fuel Gas) + (Energy by Liquid fuel)
Energy by fuel gas = 55,556 kg/day *0.5kj/kgk*(475-40) =12083.43MJ/day
Energy by liquid-fuel = 500,000 kg/day *0.5kj/kgk*(475-384) + 500,000 kg/day
*1.75kj/kgk*(384-70) =383500MJ /day
Total Energy Recovered = (383500 + 12083.43) = 395583MJ/day
Amount of cooling water @30°C required = 55.72/ (4.186*40) = 0.33 Kg /s=19008kg/day

Future Work
In the next phase of this project, we will focus on several key areas to enhance the overall
efficiency and effectiveness of the reactor and furnace system:
o Equipment Design and Selection:
o Cost Estimation:
o Performance Evaluation:

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