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All waste and organic materials in general are preferred feed stocks for the unit. The list is vast but few examples as below:
The conversion ratio is input specific. HDPE, LDPE, PP will yield highest yields of approximate 1 kg to 1.1 liters. Other plastics will have reduced yields and may yield approximately 150 to 800 ml per kg. PVC not to be used, as PET will have a higher commercial value as a recyclable material. PVC will have the lowest yield of approximately 300 ml per kg.
Yes, the feedstocks need to be sized, preferably to 2.5 inches.
No, the feedstocks are not required to be assorted/sorted. A mix of feedstocks can be fed in the unit for processing.
Specifications would be subject to per day required processing capacity of the machine.
The area required for feedstock storage depends on the waste generated/collected on daily basis for processing.
The product and by-products of the process are on the basis of the feedstocks, in general the following products and by-products are produced/generated:
The unit is highly automated with process controllers controlling the operations.
Although waste is generated every day, we suggest 7 days of feedstock to be stocked, if required. Not required for captive users.
Highly tolerable to moisture and contamination. Process can handle wet plastics having moisture up to 40% and organic contaminants. In the mixed feed stock, up to 5% PVC is tolerable.
Yes there are several units operational across India and USA
The unit does require minimum electrical power to run the pumps, motors, automation, and plant lighting.
Out of the output gas from the unit approximately 80 - 82% will be used to energize the unit.
The ideal temperature is around 360oC to 450oC.
Yes, a proprietary multifunctional catalyst is used during the process.
The patent for the same has been received from USA and South Africa.
Catalyst is supplied in kilogram which is required to be said pending on input feed.
Typically for processing 1 ton of weight in average of 150 grams - 600 grams per ton of weight could be required.
Each unit upto one ton capacity is portable and can be moved/relocated to another location easily.
The final products (fuels) have been analyzed in third party laboratory and the certification can be provided on request.
No, the fuels are not being projected as motor fuels and hence certification from authorities is not required.
The fuels have varied usage, like to fire furnaces, run generators sets and in engines of sea going vessels.
The further processing of fuels is only necessary depending on the usage.
The fuels need to be refined if required to convert it to petrol, kerosene or diesel.
The fuel output as is basis can be used for stationery engines and in case the same has to be converted to motor fuels then additional equipment is required, viz., Distillation column and de-sulphurization unit.
No certification required if the fuels are used in boiler, furnace and generator sets.
However, licensing from local authorities for sale etc. may be needed as these requirements vary from place to place and are country specified. Local requirements have to be studied and necessary permits obtained based on the location of the site where the unit is installed
Building no.7 Paynes Park Hitchin, Hertfordshire - SG5 1EH, England.
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Type of the Feedstock (content details):
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Application: Compliance, Resource Recovery/Waste Disposal
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Interest: End user/Representative/Academic/ Business.
We offer warranty on workmanship and free replacement of defective parts for a period of one year.
Our on-site supervisor will operate the unit for a period of 15 days prior to final hand over. During this period, the unit capacities will be proved and unit parameters adjusted to maximize yield from specific feedstock.
How hard is it to operate the unit and are they maintenance intensive?
It is not very difficult to operate the unit, a SOP on operation will be provided on installation of the unit.
The unit is not maintenance intensive but we advise regular maintenance to be done on a monthly basis.
The unit needs a complete shutdown to clean reactors; this is one of the most important steps of unit maintenance.
The catalytic convertors are outside the process reactors and the catalysts have to be replaced depending on the indicator.
The catalyst change does not require shut down of the reactors and the catalyst can be changed while the process is on.
The delivery lead time will depend on the size of the machine and can vary from 3 months to 12 months from the date of receipt of all payment.
The unit will be tested prior to shipment and hence least time is required for erection and commissioning of unit at site.
The product output depends upon the quality and mix of the input (feedstock).
Engineers/Operators will be provided on site training for a period of 15 days free of cost. Additionally, Operation Manual, Maintenance Manual and Safety Manual will be provided on delivery of the unit.
Additional training if required will be on chargeable basis.
The entire process is designed to function in a Closed Loop System so that the emission parameters are met easily. This unit is a zero discharge unit and therefore no air, water or other pollution.
One major area where most of the plastic-to-fuel technologies fail compared to Polycrack is the quality of fuel produced. All such technologies use a catalyst, typically metallic oxides or aluminum silicate compounds to convert the plastic to fuel. However, the fuel produced has high traces of catalyst, almost 2% to 5% residue (approximately 500 Kg to 1250 Kg) in a 25 Ton per day unit. This high volume of residue created is one reason why most plastic-to-fuel conversion units do not get environmental clearances as the residue has to be disposed. Additionally the residue is not environmental friendly.
Our process leaves no catalyst in the residues. The residue is free carbon that can be compressed into pellets and used as fuel in furnaces. A unit with capacity of 25 Tons a day using our technology would typically produce residue of about 1 ton of free flowing carbon powder which has commercial value.
Our process can handle moist & dirty plastic, mixed plastic and industrial plastic including automobile fluff.
Our process can handle mixed feedstock like plastic along with biomass, waste oil, refinery sludge etc. We can practically run all kinds of plastics including the metalized ones, plastics backed with aluminum foils, tetrapacks etc. The yields however will vary depending upon the polymer content in the input material.
The presence of metals, glass, fiber, wire, cable, organic, inorganic, TiO2 fillers etc. does not impact the process in the unit
Broadway Energy