Conversion Process

Employing Thermo Catalytic Depolymerization, the system can handle diverse types of non-recyclable plastics, decomposing them at controlled temperatures to yield high-quality fuel. Depolymerisation is the process of molecular decomposition when large molecules split into the smaller molecules. The waste plastic is converted into usable end product : synthetic oil, gas and carbon. The process takes place in a heated, sealed reactor loaded with shredded plastic. As the reactor heats up, a catalyst helps break down the long polymer chains without oxygen, creating hydrocarbon vapors. The plastic decomposes at temperatures between 380°C and 430°C, and the vapors are condensed. This condensation yields fuel and synthetic gases, with the syngas being used as an energy source to continue heating the reactor. Before this synthetic gas is reused as heat, it passes through a scrubber for cleaning, which boosts process efficiency. The fuel is filtered before collection, while non-plastic residues and any undepolymerized plastic settle at the reactor’s base and are removed after shifts or during weekly maintenance.

Output

For every 1,000 kg of plastic processed, the system produces between 450 and 800 liters of oil:

• 20 to 25% synthetic gas – used in the process
• 600 to 650 liters of poly fuel
• 5 to 10% moisture
• 5 to 10% Residual char – can be used ad road filler with bitumen. The produced fuel used directly for the burning in kerosene stoves, boilers, furnaces, certain types of gensets etc. The char produced, as the contamination of waste plastic is a non-hazardous waste.

Eco-Friendly Operations

This technology reduces greenhouse gas emissions by eliminating the need to incinerate plastic waste, instead generating usable energy in the form of oil and gases. It is one of the most sustainable approaches for plastic waste-to-energy conversion.