Title of Invention

"A PROCESS FOR PREPARATION OF FUEL FROM PLASTIC AND NON PLASTIC WASTE"

Abstract

This invention relates to a process for the preparation of fuel from plastic and non plastic waste comprises the step of mixing of shredded plastic waste such as polylofinic plastic waste and non plastic waste such as paper waste, saw dust, leaf waste and coal fines and the ratio between the plastic and non plastic waste is 10:1 to 10:5 and the mixing of plastic and non plastic waste is done in a high speed mixer or agglomerator, wherein the extruder is having temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and die zone as 110-140°C, the speed of feed rotor in the extruder is controlled at 60-100 rpm and the speed of screw barrel in the barrel of extruder is controlled at 40-80 rpm.

Full Text

FIELD OF INVENTION The invention relates to a process for the preparation of fuel from non recyclable polyolefinic plastic waste and non plastic combustible waste. PRIOR ART Global consumption of Plastics is increasing day by day. In India also, plastics are finding newer applications every day. In this scenario, plastic industry is expanding its dimensions by leaps and bounds. However, the major concern of plastic industry in India has become the handling and management of the post consumer plastic waste. Although mechanical recycling is the best option for reducing the post consumer waste, still there is a considerable amount of plastic waste that cannot be recycled effectively to valuable products. Some of these include mixed plastics, plastics having lost their mechanical strength due to repeated recycling, crosslinked plastics that cannot be recycled and plastic materials contaminated with oil or fat. In addition to this, some packaging films of low thickness and high volume are not economical for recycling purposes and hence they are not scavenged by the rag pickers. , A31 these types of plastics generally find way to landfills or remain scattered here and there causing a lot of environmental hazards. Keeping in view the above problem, an attempt has been made to utilize the wastes in making value added product called as Process Engineered Fuel. If is known, that the plastics are of petrochemical origin. Whether in the 'product form, or in the waste form the plastics have energy stored in them. Thus the recovery of this stored energy in the form of heat energy is one of ;the most important options for a viable management of plastics waste. Based on this concept, a process has been developed to convert the po!yolefinic type of plastic waste to Process Engineered Fuels ((PEF's). The formulation has been optimized and the process parameters have been Standardized to produced a range of Process Engineered Fuels. Conversion Of plastic waste to Process Engineered Fuels addresses two major issues; one is the effective disposal of the waste of great environmental concern and the other is the recovery of energy from such an important material that comprise solely of petrochemical products with high calorific value. OBJECTS OF THE INVENTION The primary object of this invention is to propose a process for the preparation of fuel from nori recyclable polyolefinic plastic waste and non plastic combustible waste. Another object of this invention is to propose a process for the preparation of fuel from non recyclable polyolefinic plastic waste and non plastic combustible waste to overcome the disadvantages of the prior art. Further object of this invention is to propose a process for the preparation of fuel from non recyclable polyolefinic plastic waste and non plastic combustible waste, which have heating values more than that of conventional fuels such as coal and biomass fuels.Still further object of this invention is to propose a process for the preparation of fuel from non recyclable polyolefinic plastic waste and non plastic combustible waste, which produces low ash and smoke. Still further object of this invention is to propose a process for the preparation of fuel from non recyclable polyolefinic plastic waste and non plastic combustible waste, which are cost effective. STATEMENT OF INVENTION According to this invention there is provided a process for the preparation of fuel from plastic and non plastic waste comprises the step of: - mixing of shredded plastic waste such as polylofinic plastic waste and non plastic waste such as paper waste, saw dust, leaf waste and coal fines and the ratio between the plastic and non plastic waste is 10:1 to 10:5 and the mixing of plastic and non plastic waste is done in a high speed mixer or agglomerator, wherein the extruder is having temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and die zone as 110-140°C, the speed of feed rotor in the extruder is controlled at 60-100 rpm and the speed of screw barrel in the barrel of extruder is controlled at 40-80 rpm. DETAIL DESCRIPTION OF THE INVENTION The present invention provides a technology for the production of marketable solid fuels based on plastics. These fuels have been characterized for physicomechnical properties and burning characteristics. It has been found that the fuels prepared from a mixture of plastic waste and other combustible wastes such as saw dust, paper waste, leaf waste, agricultural waste and rice husk provide fuel blocks with excellent burning characteristics. These fuels have been found to have heating values more than that of conventional solid fuels as coal and biomass fuels and can be used as a very good substitute for the conventional fuels. The present invention provides a process for the preparation of fuel from plastic and non plastic waste. The process comprises the following steps: plastic waste is shredded or agglomerated. Non plastic waste is shredded. Both the wastes are mixed in high speed mixer or agglomerator in the ratio of 10:1 to 10:5 by weight. The mixture thus obtained is compacted in an extruder to the desired size such as 1-3 inch in dia and 2 inch in length. The length of the fuel coming out of the extruder is maintained by controlling the speed of the rotating chopping knife. The plastic waste comprises Polyolefinic plastic waste mainly Polyethylene and Polypropylene. The non plastic wastes comprises combustible materials such as saw dust, paper waste, leaf waste, agricultural waste and rice husk. The extruder also called as briquetting machine comprises of a hopper through which shredded plastic waste already mixed with non-plastic waste is fed to the screw of the machine which rotates in a barrel having different heating zones. The extruder is having temperature of feeding zone as 100-120°C, mixing zone as 130-150° and that of die zone as 110-140°C. The speed of feed rotor is controlled at 60-100 rpm and that of screw in the barrel at 40-80 rpm. The mixture of plastic waste and non plastic waste softens as it passes through various heating zones under the shear of rotating screw. The softened material finally passes through a heated die maintained at a specified temperature and comes out continuously in the form of rod conforming to the shape of the die. There is a cutter at the output of the machine, which can be adjusted to cut the fuel blocks of the required length. The cutting length of the fuel rod is adjusted by controlling the speed of the rotating cutter. The machine has been found to be effective in comparison to other types of briquetting techniques because of the following reasons: It produces fuel blocks of uniform composition. It does not produce any dust or emissions. It consumes less power. It is easy to operate. It can produce fuel blocks of desired size. It does not require any additional cooling of the final fuel blocks. It produces fuel blocks of high strength and desired porosity. Proximate analysis of PEFs have shown the following important trends: Moisture content of PEFs is very low as compared to coal. Volatile content of PEFs is very high as compared to coal. The nitrogen content of PEFs is less than coal. PEFs have less quantity of trace elements such as cadmium, magnesia, nickel, lead, arsenic, and mercury in comparison with coal. PEFs have low sulphur content than conventional coal. Oxygen content of PEFs is lesser in comparison to coal. Trace element analysis of PEFs shows that PEF's contain considerably low quantities of hazardous trace element in comparison with coal. PEFs were also evaluated for actual burning behaviors at two industrial boilers producing steam. The results have shown that PEFs alone or in combination with coal have many advantages such as:- They have high calorific value. Emission of Nox and Sox is far less than that of coal alone. PEFs produce low ash and smoke. It has been observed during evaluation at the industrial boiler that PEFs burn rapidly and emit more CO and CH4 in comparison to coal. The reason for this has been found to be the high volatile content and low fixed carbon content of PEFs. In order to have effective burning of such fuels, the feeding rate of fuels into the boiler has to be controlled and in some cases the furnaces/boilers have to be designed in such a way that there is proper air supply during burning which leads to proper combustion of the fuels without emitting unburned CO and CH4. Results of Characterization of PEF system made from a mixture of polyolefinic plastic waste and combustible non-plastic waste in comparison with coal has been summarized in the following table: - Table: Characterization of process engineered fuels in comparison to coal (Table Removed) The fuel is advantageous to other solid fuels such as coal or biomass in many aspects. It has low content of trace elements, higher calorific value, low ash content and low harmful emissions during burning. It can be used successfully with a lot of benefits in the furnaces where there is a provision of controlled air circulation. Suspended particulate matter can be controlled with the help of bag houses. EXAMPLE 1 To obtain llkg of fuel mass, lOkgs of a mixture of polyolofinic plastic waste comprising of packaging films of polyethylene and polypropylene is shredded to pieces of the size such as 3mm in length. To this is added 1 kg of paper waste in a shredded form which is also roughly of the same size. The mixture is rotated in-a high speed mixer for about 1 minute. The mixture is fed into the hopper of an extruder with temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and that of die zone as 110-140°C. The speed of feed rotor is controlled at 60-100 rpm and that bf screw in the barrel as 40-80 rpm. The die used is having a diameter of 2 ' and the fuel rod coming out of the extruder is chopped with the help of for example: an automatically monitored chopping knife. EXAMPLE 2 To obtain 11kg of fuel mass, lOkgs of a mixture of polyethylene plastic waste comprising of packaging films of polyethylene and polypropylene is shredded to pieces of the size such as 3mm in length. To this is added 1 kg of saw dust. The mixture is rotated in a high speed mixer for about 1 minute. The mixture is fed into the hopper of an extruder having temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and that of die zone as 110-140°C. The speed of feed rotor is controlled at 60-100 rpm and that of the screw in the barrel as 40-80 rpm. The die used is having a diameter of 2" and the fuel rod coming out of the extruder is chopped with the help of for example: an automatically monitored chopping knife. EXAMPLE 3 To obtain llkg of fuel mass, lOkgs of a mixture of polyolofinic plastic waste comprising of packaging films of polyethylene and polypropylene is shredded to pieces of the size such as 3mm in length. To this is added 1 kg of leaf waste in a shredded form which is also roughly of the same size. The mixture is rotated in a high speed mixer for about 1 minute. The mixture is fed into the hopper of an extruder having temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and that of die zone as 110-140°C. The speed of feed rotor is controlled at 60-100 rpm and that of screw in the barrel as 40-80 rpm. The die used is having a diameter of 2" and the fuel rod coming out of the extruder is chopped with the help of for example: an automatically monitored chopping knife. EXAMPLE 4 To obtain llkg of fuel mass, lOkgs of a mixture of polyolofinic plastic waste comprising of packaging films of polyethylene and polypropylene is shredded to pieces of the size such as 3mm in length. To this is added 1 kg of coal fines in a shredded form which is also roughly of the same size. The mixture is rotated in a high speed mixer for about 1 minute. The mixture is fed into the hopper of an extruder having temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and that of die zone as 110-140°C. The speed of feed rotor is controlled at 60-100 rpm and that of screw in the barrel as 40-80 rpm. The die used is having a diameter of 2" and the fuel rod coming out of the extruder is chopped with the help of for example: an automatically monitored chopping knife. It is to be noted that the present invention is susceptible to modifications, changes, adaptations by those skilled in the art. Such modifications, changes adaptations are intended to be within the scope of the present invention which is further set forth under the following claims. WE CLAIM; 1. A process for the preparation of fuel from plastic and non plastic waste comprises the step of: - mixing of shredded plastic waste such as polylofinic plastic waste and non plastic waste such as paper waste, saw dust, leaf waste and coal fines and the ratio between the plastic and non plastic waste is 10:1 to 10:5 and the mixing of plastic and non plastic waste is done in a high speed mixer or agglomerator, wherein the extruder is having temperature of feeding zone as 100-120°C, mixing zone as 130-150°C and die zone as 110-140°C, the speed of feed rotor in the extruder is controlled at 60-100 rpm and the speed of screw barrel in the barrel of extruder is controlled at 40-80 rpm. 2. A process for the preparation of fuel from plastic and non plastic waste substantially as herein described with reference to illustrated examples.

Documents:

1427-DEL-2005-Abstract-(06-02-2009).pdf

1427-DEL-2005-Abstract-(07-01-2010).pdf

1427-del-2005-abstract.pdf

1427-DEL-2005-Claims-(06-02-2009).pdf

1427-DEL-2005-Claims-(07-01-2010).pdf

1427-del-2005-claims.pdf

1427-DEL-2005-Correspondence-Others-(06-02-2009).pdf

1427-DEL-2005-Correspondence-Others-(07-01-2010).pdf

1427-del-2005-correspondence-others.pdf

1427-del-2005-correspondence-po.pdf

1427-DEL-2005-Description (Complete)-(06-02-2009).pdf

1427-DEL-2005-Description (Complete)-(07-01-2010).pdf

1427-del-2005-description (complete).pdf

1427-DEL-2005-Form-1-(06-02-2009).pdf

1427-del-2005-form-1.pdf

1427-del-2005-form-18.pdf

1427-del-2005-form-2.pdf

1427-DEL-2005-Form-3-(06-02-2009).pdf