Negzhi micro-pyrolyser

Small scale and portable Negzhi micro-pyrolyser installed in any communities to convert their generated plastic waste into economic sustainable energy sources developing net-zero waste communities

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Inspiration

We wanted to reduce carbon footprint caused by PPE plastic waste and create a sustainable method of recycling plastic wastes efficiently and cost effectively. The existing methods are not eco-friendly and the waste are reaching landfill sites directly from communities. There is a need of recycling PPE plastic waste within the community blocking it from reaching landfill sites and also gaining useful products out of them. The passion towards entrepreneurship engaged us in making a sustainable solution for energy crisis and plastic waste management. Also delivering high demand products out of plastic waste.

What it does

The proposed innovation negizhi micro-pyrolyser is a small scale and portable plastic pyrolysis unit which can be installed in any communities to recycle their generated plastic waste and convert them into economic sustainable energy sources developing net-zero waste communities. The PPE plastic waste produced in the community is recycled on the same day. 

How we built it

The reactor of the Negzhi micro-pyrolyser is made of stainless steel 310 grade which can withstand high temperature for extended lifespans. Industrial nichrome electrical heater is used as the heating source for the reactor. The reactor is packed with glass wool to eliminate the loss of heat. The condenser made of SS 316 material and copper tube is used inside the condenser for better cooling of gas. The outer covering is done with mild steel & stainless steel material improves strength and safe to be installed. The dimensions of the single unit is 6x3x3 feet, which is easily portable and can work in any circumstances self sustainably.

How different is our innovation?

The existing plastic pyrolysis is only done in larger scale and not feasible to fit within a community because the hazardous non-condensable is gas left in open atmosphere possessing threat to the residents. Our innovative micro-pyrolyzer best suits to fit in a community. The Micro-pyrolyser is a small scale, portable and efficient plastic pyrolysis machine which is safe to the environment because the non-condensable gas is used to produce electricity and also 1 atmospheric pressure is held inside the pyrolysis reactor which makes our innovation community-friendly and installable in residential areas.

Plastics can be converted into fuel because they are primarily derived from petroleum. This means plastics are rich in hydrocarbons, the same components found in gasoline, diesel, and other fuels. So, it is possible to convert plastic back into fuel (reverse engineering). The reactor is heated at 400-450 degrees Celsius using the electrical heater, by the process of pyrolysis, that results in the breakage of long hydrocarbon chain of plastic waste and formation of vapour. This vapour is sent into two condensing chambers that cools the vapour into liquid.

The products obtained from waste plastic after the process are liquid fuels, gas (equivalent to that of LPG) and activated carbon black. About 70% of pyrolysis oil can be obtained from plastics through this process. This pyrolysis oil is distilled to obtain pyro petrol(40%) and diesel(60%) which are similar to market fuel. The activated carbon char(15%) is subjected to catalytic graphitisation through which they are can be converted to graphite product, this graphite can be used as battery electrode.There is a small amount(15%) of non-condensible gas exits throughout the process. The non condensible gas is used as a fuel in dual-fuel generators to produce electricity and the electricity is used as a source for the reactor’s electrical heater; thus, there is no need for any chimneys for our proposed work because it is a closed-loop system.  The process innovation is a self-sustainable and cost friendly process because the raw material(plastic waste) is in abundance.

The micro-pyrolyser can be installed in each ward according to their waste generation. For example every ward in Chennai produces 250Kg of plastic waste per day. Micro-pyrolyser installed in the ward and processed can produce 70L of pyro petrol, 105L of pyro diesel and 35kg of activated char. These products are in high demand can be sold easily among the community, an estimation of Rs.12,950 can be generated from each ward per day in Chennai(Chennai contains 200 wards). The process is profitable for both the communities and the unit. To ensure the validation is done by different types of groups such as government officials, academic officials and industry engineer. It is to be noted that the proposed solution showed superiority than the existing methods. Micro-pyrolyser can process 1kg - 1000kg per according to the community requirements. Micro-pyrolyser doesn’t require any chimney unlike the existing process because the usage of gas to produce electricity. The innovative schematism is self-sustainable process.

Micro-pyrolyser creates great impact on the environment and peoples such as creating net-zero waste & emission-free community, low cost products for everyone. Waste generated in a day is recycled in the same day reducing mismanagement of waste. The innovation maps 4 SDG goals such as sustainable cities and communities, responsible consumption and production, affordable and clean energy and climate action. Also comes under Swachh Bharat and Viksit Bharat.The innovation accounts great benefits for the people and the society such as earning incentives, low-cost and superior fuel and the eliminating the need of segregation plants

Challenges we ran into

We took multiple testing in choosing correct materials for reactor and condenser. Converting the non-condensable gas into electricity using dual-fuel generator which required changes in generator to use the gas. Dirty Pyrolysis oil was achieved which is rectified using catalyst

Accomplishments that we're proud of

Negzhi micro-pyrolyser has been shortlisted in Himalayan startup trek and MSME. And won in various inter and intra college events.

What we learned

Starting from the pollutions caused by plastic waste and need of waste management. Conversion of plastic waste into useful products within communities without polluting the environment creating net-zero waste communities. Catalytic and non-catalytic pyrolysis process and effective & innovative use of produced materials.

What's next for Negzhi micro-pyrolyser

Next step for Negzhi micro-pyrolyser is to make it a fully commercial product and install in different regions within India to process the community waste generated and produce net-zero plastic waste and generate revenue. Job opportunities provided for young youths in each unit.

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