Blest Plastic-to-Fuel Project Report Results and Recommendations for a Northern Norther n Climate
This publicaon may be obtained from:
Cold Climate Innovaon Yukon Research Centre, Yukon College 520 College Drive PO Box 2799 Whitehorse, Yukon Y1A 5K4 t. 867.668.9995 1.800.661.0504 www.yukoncollege.yk.ca/research
Recommended citaon:
Cold Climate Innovaon, 2014. Blest Plasc-to-Fuel Project Report - Results and Recommendaons for a Northern Climate. Yukon Research Centre, Yukon College, 16 p.
Front cover photograph: Blest B-240/NVG 200 plasc-to-fuel processing machine. Printed in Whitehorse, Yukon, Yukon, 2014 by Arcc Star Prinng Inc., 204 Strickland St.
Blest Plastic to Fuel
EXECUTIVE SUMMARY The Blest B-240 plasc-to-fuel machine has met or exceeded our expectaons. Several important factors were considered during this project including environmental, economical, and operaonal factors. The machine is also adaptable to many dierent installaon possibilies. From an environmental standpoint, standpoint, the machine is more ecient and has lower emissions than tradional recycling. The CO2 emissions from the machine are just 186 g per kg of plasc processed, compared with as much as 3500 g per kg processed using tradional recycling methods. The machine meets environmen e nvironmental tal regulaons in Yukon Yukon as well as other jurisdicons that have much stricter emissions standards (e.g., Japan, Ice land, Slovakia, Palau, Oregon, California, New York, York, Georgia and Brish Columbia). This machine also helps to deal with plasc that is currently unsellable due to China’ China’ss new “Green Fence Policy” Policy”,, which limits what grades of plascs can be exported. Results of the emissions tesng have indicated that there are no concerns with the emissions from the machine.
T . Parameter
Result
Expected result
CO2
186 g/kg plastic
250 g/kg plastic
methane
10 ppm
25 ppm
TVOCs
<1 ppm (undetectable)
1 ppm
NOx
<4 ppm
<10 ppm
SOx
<5 ppm
<15 ppm
Note: TVOC = total volale organic compounds; NOx = nitrogen oxides; SOx = sulfur oxides Economical invesgaons invesgaons have successfully demonstrated that the Blest B-240 turns waste plasc that has a negave economic value (i.e., shipping costs exceed value of product) into a high-prot product. The B-240(NVG 220) machine is capable of producing 1 L of fuel at a cost as low as $0.31 per litre; larger machines produce the fuel at $0 .14 per litre. Gasoline and diesel equivalents can be produced with the installaon of an oponal inline disllaon unit, which allows these fuels to be used anywhere gasoline and diesel are used. The operaons of the machine are simple and can be taught to users in 2 to 3 hours. Operaon of the machine can also be accomplished through remote access via a secure I nternet connecon. The machine operated well in a variety of temperature condions, as well as with a variety of feedstock. The plasc types that can be processed include:
#2 Poly Ethylene (e.g., HDPE, UHMWPE, etc.)
#3 Poly Vinyl Chloride (when processed with the t he new oponal pre-processor)
#4 Low Density Poly Ethylene
#5 Poly Propylene (e.g., PP, HDPP, UHMWPP, etc.)
#6 Poly Styrene (e.g., PS, EPS, HDPS, HIPS, etc.)*
ABS (With an oponal o-gas lter)
Blest Plastic to Fuel
*When processing #6 Polystyrene, styrene monomer can be produced and sold to manufacturers to make new polystyrene products. This is currently feasible with a larger model of the machine (NVG 1000) as the B-240(NVG 220) does not process enough to sasfy chemical brokers minimum sales requirements. #1 PETE plasc is considered a high-value product and can generally be recycled by tradional methods. #7 OTHER plascs are a mix of resins and may include a combinaon of resins such as Nylon and Polyethylene Polyeth ylene making recycling by any method dicult. In communies with populaons as low as 200 people, benets from the installaon of such a machine could be realized. In parcular, remote and arcc communies would see the greatest benets where fuel costs are high due to barged or own-in fuel, and where there are waste disposal problems such as open-burning in landlls. Many organizaons (e.g., private recycling companies, NGOs, etc.) are also considering this technology as a means of processing marinesourced plasc that may be unrecyclable due to the accumulated salt concentraons in the plasc. The Blest plasc-to-fuel machine is also ideally suited for use in an industrial seng where waste plasc from manufacturing or processing can be directly used as the feedstock. A mobile or travelling scenario for the Blest B-240 was explored, however, minimal operaonal operaonal sta requirements and high transportaon and standby labour costs suggest that a staonary installaon of the machine is more suitable. However, one machine has been mounted on a truck that travelled extensively in India and Nepal as an environmental demonstraon demonstraon project. This environmental demonstraon demonstraon project was not intended to be economically feasible, so labour costs were not a consideraon.
Blest Plastic to Fuel
TABLE OF CONTE NTS ........................................ .......................................... .......................................... .......................................... .......................................... ....................................i ...............i Executive Summary ...................
Introduction ..................... .......................................... .......................................... .......................................... ......................................... ......................................... .......................................... .......................... ..... 1 Blest Models .................. ....................................... .......................................... .......................................... .......................................... .......................................... .......................................... ............................. ........2 Addional Opons ..................... .......................................... .......................................... .......................................... .......................................... .......................................... ................................... ..............2 Peripherals .................... ......................................... .......................................... .......................................... .......................................... .......................................... .......................................... ............................. ........ 3 .......................................... .......................................... .......................................... .......................................... ......................................... ......................................... .......................... ..... 3 Cost Analyses.....................
Maintenance Costs..................... .......................................... .......................................... .......................................... .......................................... .......................................... ................................... .............. 4
Environmental Analyses ..................... .......................................... .......................................... .......................................... .......................................... .......................................... ....................... ..4 O-Gas Tesng ..................... .......................................... ......................................... ......................................... .......................................... .......................................... .......................................... ....................... 5 Fuel Tesng ................... ........................................ .......................................... .......................................... .......................................... .......................................... .......................................... ............................. ........ 5 Water ................... ........................................ .......................................... .......................................... .......................................... .......................................... .......................................... .................................5 ............5 ........................................ ......................................... ......................................... .......................................... .......................................... ...................................5 ..............5 Copper corrosion ................... Pour/plug points ................... ........................................ .......................................... .......................................... .......................................... .......................................... ...................................6 ..............6 Flash point ..................... .......................................... .......................................... .......................................... .......................................... .......................................... .......................................... ....................... 6 ......................................... .......................................... .......................................... .......................................... .......................................... .......................................... ............................. ........ 6 Sulphur .................... Output Contaminant Tesng ................... ........................................ .......................................... .......................................... .......................................... ........................................ ................... 7 Contaminant tesng .................... ......................................... .......................................... .......................................... .......................................... .......................................... ........................... ......7 Fuel volales tesng .................... ......................................... .......................................... .......................................... .......................................... .......................................... ........................... ......7 Internal Combuson Engine Tesng .................... ......................................... ......................................... ......................................... .......................................... .............................8 ........8
Processing Expanded Polystyrene (EPS) ..................... .......................................... .......................................... .......................................... ..................................8 .............8 EPS Foam Quality .................... ......................................... .......................................... .......................................... ......................................... ......................................... .......................................8 ..................8
Comparing Recycling to Plastic-to-Fuel Processing .................... ......................................... .......................................... ............................... ..........9 Energy Usage ................... ........................................ .......................................... .......................................... .......................................... .......................................... .......................................... ......................... .... 9 CO2 Emissions ................... ........................................ .......................................... .......................................... .......................................... ..................................................... .............................................. ..............9
Remote Access ................... ........................................ .......................................... .......................................... .......................................... .......................................... ......................................... ....................... ... 10 Recommendaons for Remote Access ................... ........................................ ......................................... ......................................... .......................................... ....................... ..10 10
Containerization .................... ......................................... .......................................... .......................................... .......................................... .......................................... .....................................10 ................10 .......................................... .......................................... .......................................... .......................................... .......................................... .....................................11 ................11 Power supply ..................... .......................................... .......................................... .......................................... .......................................... .......................................... .............................11 ........11 Glass glycol tubes ..................... Glycol reservoir ..................... .......................................... .......................................... .......................................... .......................................... .......................................... .................................11 ............11 Glycol chiller ................... ........................................ .......................................... .......................................... .......................................... ......................................... ........................................11 ....................11 ........................................ ......................................... .......................................... .......................................... .......................................... .....................................11 ................11 Load cell scale .................... O take tank ................... ........................................ .......................................... .......................................... .......................................... ......................................... ........................................11 ....................11 Reactor and buer tank hangers ................... ........................................ .......................................... .......................................... .......................................... ..........................11 .....11 Levelling .................. ....................................... .......................................... .......................................... .......................................... .......................................... .......................................... ........................... ...... 11 Molten plasc in reactor ..................... .......................................... .......................................... .......................................... .......................................... ......................................12 .................12
Blest Plastic to Fuel
Community Size and Feasibility ................... ........................................ .......................................... .......................................... .......................................... ..............................12 .........12 Populaon Consideraons .................... ......................................... .......................................... .......................................... .......................................... ..........................................13 .....................13 ....................................... .......................................... .......................................... .......................................... ..................................13 .............13 Factors Affecting Operations ..................
Humidity of Feedstock ................... ........................................ .......................................... .......................................... .......................................... .......................................... .............................13 ........13 Calibraon for moisture .................. ....................................... .......................................... .......................................... .......................................... ..........................................14 .....................14 Plasc Types ..................... .......................................... ......................................... ......................................... .......................................... .......................................... .......................................... ........................ ... 14 Calibraon for plasc type .................. ....................................... .......................................... .......................................... .......................................... ......................................14 .................14 Fuel Output Quality ................... ........................................ .......................................... .......................................... .......................................... .......................................... .................................14 ............14 Adjustments for fuel output quality ..................... .......................................... .......................................... .......................................... ........................................14 ...................14 Feedstock .................. ....................................... .......................................... .......................................... .......................................... .......................................... .......................................... ...............................14 ..........14 Ambient Temperatures .................. ....................................... .......................................... .......................................... .......................................... .......................................... .............................14 ........14 Ambient temperatures temperatures encountered encountered .................... ......................................... .......................................... .......................................... ........................................14 ...................14 Cold temperature operang guidelines .................. ....................................... .......................................... .......................................... ....................................15 ...............15 Fuel Output .................. ....................................... .......................................... .......................................... .......................................... .......................................... .......................................... ........................... ...... 15
Troubleshooting/Repairs .................. ....................................... .......................................... .......................................... .......................................... ..........................................15 .....................15 ....................................... .......................................... .......................................... .......................................... .......................................... .......................................... ........................... ...... 16 Bibliography ..................
Introduction
INTRODUCTION Plasc accounts for >12% of all materials deposited in landlls, placing an ever-increasing burden on the environment. Furthermore, iniaves such as C hina’ hina’ss Green Fence Policy, which limits the ability to dispose of plasc products, has resulted in a growing requirement for iniaves that will reduce the environmental impact of plasc. Thermal depolymerizaon is a process that uses pyrolysis for the reducon of complex materials (in this case plasc) into light crude oil and essenally mimics natural geological processes. Under pressure and heat, long-chain polymers of hydrogen, oxygen oxygen and carbon decompose into short-chain petroleum hydrocarbons hydrocarbons which can then be used for heang or transport applicaons. One of the leading global proponents for ulizing pyrolysis technology to address the plascs issue is Blest, a Japanese company established by inventor Akinori Ito. Movated by declining convenonal oil reserves and increasing plasc polluon, Ito sought to adapt exisng pyrolysis technology to create community-sca community-scale, le, plasc-to-fuel processors. To date, Blest is developing and manufacturing a wide range of plasc-to-fuel machines and are increasing their global distribuon network. Following the recommendaons of a 2011 feasibility study conducted by Rising Sun Innovaons, a Blest B-240 plasc-to-fuel machine was procured in 2012 under the partnership of Canadian Northern Economic Development Agency (CanNor), Yuk Yukon on Research Centre and Cold Climate Innovaon. The purpose of the procurement was to house the B-240 in a Whitehorse recycling centre (P&M Recycling), in order to determine if it was economically and environmentally environmentally viable to up-cycle plasc to fuel, rather than follow tradional recycling methods. It was envisaged that this process would not only reduce the burden on local landlls, or remove the necessity to transport plascs out of territory and ulmately overseas, but would also have the potenal to generate locally produced fuels that have an intrinsic commercial value. The inial phase of the project concluded with the successful installaon and operaon of the Blest B-240 machine. Phase 2 of the project included a detailed analysis of the fuel produced by dierent types of plasc, an assessment of emissions produced by the machine and internal combuson engine, and nally an assessment with recommendaons as to the feasibility of deploying the machine to remote northern communies. This report summarizes the work completed to date, details the ndings of the fuel analysis, and makes recommendaons as to which Blest machine is most suitable depending on community size. It is envisaged e nvisaged that this report will beer prepare individuals and communies to assess the economic and environmental viability of moving from convenonal plasc recycling to upcycling, which produces usable fuel.
Blest Plastic to Fuel
BLEST MODELS Blest manufactures several capacies of machines to suit dierent feedstock amounts. The size of a machine purchased should match the t he amount of plasc available. A table providing dierent machine sizes and their corresponding esmated annual fuel producon and Return on Investment (ROI) is provided below.
T B . Machine size
Maximum community size (no. of people)
Amount of plastic per year (kg)
Potential annual fuel production (litres)
ROI (min. in years)
NVG 220
200 - 1400
80 300
8 0 30 0
7
NVG 1000
6 30 0
365 000
3 65 00 0
3
NVG 2000
13,000
730 000
7 30 00 0
2.25
NVG 4000
26,000
1 460 00 0
1 460 000
2
NVG 6000
38,000
2 190 00 0
2 190 000
1.75
NVG 8000
52,000
2 920 00 0
2 920 000
1.5
20 tonnes
126,000
7 30 0 0 00
7 300 000
1.25
ADDITIONAL OPTIONS As well as dierent sizes of machines, dierent opons are available depending on what the feedstock is and the desired output of fuel is. 1. Film opon: a. Processes lm and low-density plascs 2. Rener opon: a. Inline i. Produces diesel and gasoline ii. Uses no extra electricity iii. Uses no extra labour b. BOR 20/50 i. Produces gasoline, diesel, kerosene, #2 oil ii. Uses 1 kWh extra per litre iii. Extra labour needed 3. PVC opon: a. Processes PVC plasc b. Outputs salt and oil c.
Extra energy required
Cost Analyses
4. Cold weather kit: a. Allows operaon below specied temperatures b. Extra energy required 5. Heavy moisture opon: a. Reduces moisture content in very wet materials b. Extra energy required
PERIPHERALS As well as the machine sizing to feedstock and machine opons, the peripherals need to be sized to match the needs of the feedstock. The peripherals include:
S: Takes large materials down in size for the granulator (conveyor to granulator). S: Takes G: Reduces the size of material so it will feed properly into the machine G: Reduces (conveyorr from granulator to hopper/feed system). (conveyo F : Appropriate : Appropriate sizes and types of containers.
COST ANALYSES Various cost analyses were performed in order to dene variables such as cost per litre of Various product, cost at dierent throughputs, as well as general maintenance costs. Results are provided in the tables below.
T . Test #
Kg processed
Litres produced
kWh used*
Labour
Cost/litre
1
64
63
64
24.1
0.504
2
42
47
54
17.98
0.52
3
82
79
77
30.22
0.499
4
75
77
75
29.46
0.5
5
87
88
82
33.66
0.494
6
88
88
84
33.66
0.494
7
92
91
92
34.81
0.497
8
30
25
32
9.57
0.504
9
55
56
55
21.43
0.536
10
57
54
56
20.66
0.507
11
43
34
40
13
0.523
12
14
10
18
3.83
0.599
Average cost per litre = $0.515 *
This did not account for granulator power (esmated at ~$0.01/litre).
Blest Plastic to Fuel
T .
e r u t a r e p m e T
r e p e t g u a s p n u i y g g r k e n E
t u p @ h r h t o s W e g t r u a o l t c k o i / l u r y 2 / n r h g 1 t . r 0 u r a e o r g n $ b h n E @ a / g L k o 0 2
t u p @ h r o g t e r u a l t o i l u r / n r h t u r a o r g b h / a g n L k o 0 5
r n h / o 8 1 e r $ t i l @ / r e u i n o h b c a L a m
r h / * g t k u 0 p 2 h e r g t i u o l r / t h s t o C
r h / * g k t u 0 p 5 h g e r u t i o l r / t h s t o C
r h / g * k t 0 u p 5 h 1 g e r u t o i r l / h t s t o C
-1°C
0.89 – 1.1 kWh
$0.11 $0.13
$0.75
$0.30
$0.09
~$0.99
~$0.52
~$0.31
0°C
0.92 – 1.2 kWh
$0.11 $0.14
$0.75
$0.30
$0.09
~$0.995
~$0.525
~$0.31
+20°C
0.98 – 1 kWh
$0.12
$0.75
$0.30
$0.09
~$0.99
~$0.52
~$0.31
* Throughput on granulator is the main labour cost, thus the main consideraon on cost per litre.
This cost includes electrical costs for the granulator. Ambient air temperatures were recorded using a Hobo U30 Data Logger. The minimum recorded ambient room temperature between 1/21/2013 and 10/31/2013 was -2.073°C. The maximum ambient room temperature in the same me period was +28.593°C. Temperature had lile eect on the energy consumpon of the machine. In fact, the lowest energy usage was observed at -1°C ambient temperature. The insulaon on the machine is therefore eecve at retaining the heat. Furthermore, the reduced energy consumpon could be due to lower usage of the chiller at theses temperatures since the ambient temperature around the condenser is adequate to chill the pyrolysis gas. The largest cost is associated with the inial granulang process of the plasc. This cost could be reduced by installing a shredder before the granulator granulator,, as the granulaon process is me consuming. At 150 kg/hr throughput, the cost per litre is reduced to $0.31/litre.
MAINTENANCE COSTS There are two main components included in the maintenance cost: 1.
C : 1 : 1 day every 3 months = $960/year @ $30/hr. $30/hr. This has very lile impact on fuel cost. If the machine was running at full output, this amounts to $0.016/litre
2.
S : 3 : 3 to 4 mes/year = $120 = 2/10 of a cent increase to fuel price.
ENVIRONMENTAL ENVIRO NMENTAL ANALYSES ANALYSES Yukon Environment was consulted on the project, and since there is no signicant waste or Yukon emissions associated with the process, there are no perming requirements. Janine Kostelnik, Environment Environment Yukon Yukon
“it has been determined that the Plasc to Fuel pilot project, is not an
Environmental Analyses
acvity that is captured under the Environment Act, or any of the regulaons (Air Emissions, Solid Waste, Special Waste). As such, we are not able to require emissions tesng or any other operaonal requirements related to the unit.” However, tesng has been completed on all the outputs of the Blest machine. This tesng was However, completed to the lowest detectable limits available. Four main tests were performed: 1.
O-gas tesng was completed in Japan on an idencal machine.
2.
Fuel-tesng was completed by Polaris Laboratories in Calgary, AB.
3.
Fuel tesng for contaminants was completed by CH2M Hill Applied Sciences Laboratories in Corvallis, OR.
4.
Carbon char contaminant tesng was performed by CH2M Hill Applied Sciences Laboratories in Corvallis, OR.
OFFGAS TESTING O-gas emissions’ tesng was completed by JFE Techno Research Co. Ltd. The samples were collected in Tetra Teon Teon coated bags in accordance with JIS standards and tested with MS/GC methods. Tesng Tesng was conducted with a standard o-gas lter at 164.9 l/h o-gas output. Results are as follows:
CO2 emissions amount to 186 g per kg of plasc input.
Methane (CH4) levels were negligible at 10 ppm.
No combuson NOX was produced, and only barely detectable amounts of thermal NOx were produced.
T ’ . Emission
Volume
carbon dioxide
6.70%
oxygen
3.61%
CH4
<1 ppm
Polaris Laboratories in Edmonton, as well as Econo-Tech Labs in Vancouver tested the fuel produced by the Blest B-240.
C2H4
<1 ppm
The following results were obtained:
C2H6
<1 ppm
C3H8
<1 ppm
C2H9
<1 ppm
FUEL TESTING
Water
The water test measured the total dissolved water content of the fuel. Early results from i-C4H10 <1 ppm tesng of the fuel indicated high water content n-C4H10 <1 ppm and were likely due to PET contaminaon in the cis-2-C4H8 <1 ppm feedstock. Eliminaon Eliminaon of the PET resulted in a reducon in the water content to 0.005%; this nitrogen oxide <4 ppm is well below requirements and specicaons sulphur oxide <5 ppm for diesel fuel of 0.02%. This test clearly demonstrates the need to carefully sort the plasc feedstock prior to processing in the machine. Copper corrosion
This test indicates if the fuel is corrosive to copper. Tesng resulted in a 1a rang. The maximum
Blest Plastic to Fuel
rang set out by ASTM Internaonal I nternaonal standards standards is 3 and therefore the fuel is considered to not be corrosive to copper. Pour/plug points
Pour and plug points indicate usability in cold weather condions. The pour point is -9 to -12°C; below this temperature the fuel will not ow readily. The plug point is -5 to -8°C; below this temperature the fuel will plug a lter lter.. These results were expected, as the fuel produced is a crude oil. With further rening, the fuel would have a lower pour/plug point. Results indicate that the fuel is best used indoors or with a heated tank unless it is rened. Flash point
The ash point measures the minimum temperature at which the fuel vaporizes to form an ignitable mixture in air. air. The test results produced a Pensky-Mart Pensky-Marten en ash point of 52°C; this is idencal to diesel fuel. Sulphur
Sulphur concentraons were measured on several samples. One sample indicated a higher-thanexpected sulphur content of 32 ppm; 15 ppm was the expected result. However, one sample had a measured concentraon of sulphur of 12ppm. The higher result was determined to originate from a run of plasc that had a “pipe dope” on the threads. Upon examinaon of the MSDS, there was a sulphur compound listed on the pipe dope.
T .
Analysis
water
Desired result
) c i t 1 s a t l l p u s d e e R i x m (
2 ) t l E P u s D e H R (
) c i t 3 s a t l l p u s d e e R i x m (
d e 4 i x t ) l m S u , s y P e t r R i d (
e t i 5 h t l w ) , S u s n P e a E R l e c (
<0.02%
>0.2%*
copper corrosion
<3
1B
1A
1A
pour point
<-5c
- 17
-9
-12
plug point
<-5c
-12c
-5
-8
flash point
~52
min. 52
~55
sulphur
<15 ppm
0.01%
12
bacteria and mold ash content
0.01%
6 t l ) P u s P e ( R
7 0
100 ppm -0.01%
viscosity
0
0.00%
0.00%
1.6
lubricity
<520
monomer
>99.7
305
375
3 34 99.71
99.88
* Failed result; high-water content due to accidental processing of #1PETE and nylon. Notes: blank cells = not tested; HDPE = high-density polyethylene; PS = polysterene; EPS = expanded polysterene; PP = polypropelene
Environmental Analyses
Tesng has indicated that feedstock types aect the quality of the fuel output. Plascs that are not recommended can aect fuel quality such as PET#1 which produces water. water. Plasc type #4 LDPE was not tested because this would require a lm opon on the machine, which was not available at the me of purchase of the test pilot machine. The low density of LDPE causes feeding problems without the lm opon.
OUTPUT CONT CONTAMINANT AMINANT TESTING Contaminant testing
Fuel tesng for concentraons of various contaminants and volales were measured by CH2M Hill Applied Science Laboratories. The results are provided in the following tables.
T . Contaminant
Concentration (ppm)
Detection limit
arsenic
0.03
below detection limit
barium
0.017
below detection limit
cadmium
0.008
none detected
chromium
13.3
from “pipe dope”
lead
0.35
from “pipe dope”
mercury
0.000
undetected
selenium
0.029
undetected
silver
0.092
undetected
With the excepon of chromium and lead, all values were either none detected (U) or below the detecon limit (J). The higher chromium and lead values were found to be due to a test sample consisng of well pipe caps from a natural gas facility. facility. These pipe caps had a thread dope applied on the plasc; the MSDS indicated chromium and lead constuents in the thread dope. Fuel volatiles testing
Tesng for fuel volales was performed by gas spectrometry and mass spectrometer analyses. Results are provided in the following table.
T . Volatile compound
Fuel sample
Carbon char sample
vinyl chloride
undetectable
undetectable
1,1-dichloroethene
undetectable
undetectable
2-butonone
undetectable
undetectable
chloroform
undetectable
undetectable
1,2-dichloroethane
undetectable
undetectable
carbon tetrachloride
undetectable
undetectable
benzene
undetectable
undetectable
trichloroethene
undetectable
undetectable
tetrachloroethene
undetectable
undetectable
Blest Plastic to Fuel
T , connued . Volatile compound
Fuel sample
Carbon char sample
chlorobenzene
undetectable
undetectable
1,4-dichlorobenzene
undetectable
undetectable
hexachlorobutadiene
undetectable
undetectable
INTERNAL COMBUSTION ENGINE TESTING The fuel was tested on an engine-driven generator (generator type: ME-531A /2kW 120V; fuel consumpon: 0.946 litre/hr). Results of this test are as follows:
T . O2 (%)
CO (ppm)
NO (ppm)
NOx (ppm)
NO2 (ppm)
SO2 (ppm)
CO2 (ppm)
baseline diesel
21
129
1
4
3
10
1.4
running on plastic fuel
19.8
77
3
4
0
11
1
This test demonstrated that the emissions from the engine were similar to, or lower than running on regular diesel fuel.
PROCESSING PROCESSI NG EXPANDED POLYSTYRENE POLYSTYRENE EPS Due to the low specic gravity of EPS, the machine cannot handle this material unless it is densied. A densier for EPS costs ~$6,000 to $24,000 depending on size requirements. Densied EPS can be processed in the machine to produce styrene monomers. The value of these monomers uctuates and can be up to $1,800/tonne ($1.80/litre). Shipping costs are $100/tonne, making these monomers potenally the most valuable recyclable material. However,, chemical broker However brokerss were contacted and required a minimum quanty of 90 barrels. This would take 3 months of producon to fulll this order with the current machine; however, however, an NVG 5000 machine could produce 90 barrels in 4 days. This limits the usefulness of styrene monomer producon to the larger centres that have ready access to shipping terminals. Markets for the monomers are primarily polysterene (PS) manufacturers located in large centres. The manufacturers that would most likely buy the product are foam extruders that make insulaon materials for the construcon industry. industry. Some of these manufacturers are located in Edmonton, Vancouver Vancouver and Anchorage. Styrene monomers rapidly degrade into dimers and trimers without the addion of chilling, circulaon and stabilizers. stabilizers. Unstabilized monomers would need to be shipped out within 2 to 3 weeks to reduce storage costs associated with chilling, circulaon and stabilizaon.
EPS FOAM QUALITY Unlike tradional EPS recycling, the machine will handle any quality of foam. Dirty or coloured foam should not aect the quality of the monomers produced. This is a benet that allows the
Comparing Recycling to Plastic-to-Fuel Processing
processing of foam that is currently not accepted by tradional recyclers. The styrene monomers produced could then be ulized to make new EPS of equal or greater quality. quality. This is unlike tradional EPS recycling that downgrades the product into a less useful and less recyclable form.
COMPARING RECYCLING TO PLASTICTOFUEL PROCESSING Recycling of plasc requires sorng, granulang, washing and pellezing the resin in order to use it as feedstock for new plasc. In the broadest sense, this is pung the plasc back into the producon loop. Realiscally, the plasc is also down-cycled in the process. This is something that occurs when Realiscally, the plasc resins produced are of a lower quality than the original material. For example, dierent resins of plasc can be mixed together and the new hybrid product is of a lower quality than the original plasc. In order to achieve the highest quality possible in the new plasc, careful sorng of the resins is necessary in order to reduce contaminaon. As well, due to China’s Green Fence policy, mixed plascs that are uneconomical to recycle are now being landlled or incinerated in a waste-toenergy plant. The cost of this disposal is being charged to the shipper of these uneconomical plascs (i.e., #3 to#7) at a rate of up to $237/tonne. “We are now only accepng HDPE (#2) and PETE (#1). Do not send us any mixed plascs anymore, we will have to charge you y ou a disposal fee of $237/tonne if you do” recycling buyer, Vancouver. “Since China’s green fence policy, policy, 1/3 of our plasc recycling is going to the landll as we have no markets for it” unnamed Vancouver area recycling company that is considering a plasc-to-fuel machine to deal with this waste. With the plasc-to-fuel process, the plasc is being up-cycled. Up-cycling is a process where the material is made into a product of greater quality and/or lower environmental consequence. Furthermore, up-cycling oen results in an increase in the monetary value of the product. Upcycling is considered an important aspect of a zero-waste iniave. The fuel produced could be used as a feedstock to make synthec plasc of greater quality compared with the original feedstock. However, However, it is important to note that the goal of this pilot project is to reduce the import of fossil fuels and thus to produce fuels that could be used locally as heang fuel.
ENERGY USAGE Localized processing of materials reduces energy usage by about 25% compared to outsourcing the processing elsewhere.
CO 2 EMISSIONS In addion to a reducon in energy consumpon, CO2 emissions are dramacally reduced making the process a carbon-reducing technology that is cered by the United Naons Environmentt Program. Environmen A comparison of the energy usage and CO2 emissions from convenonal recycling methods versus plasc to fuel is presented in the following tables.
Blest Plastic to Fuel
T . . Recycling
Plastic to fuel
4735 47 35 bt btu/ u/kg kg en ener ergy gy us used ed to re recy cycl cle e pla plast stic ic
3412 34 12 bt btu/ u/kg kg pl plas asti ticc to to fue fuell ene energ rgyy use used d
1852 18 52 btu btu/k /kg g tran transp sport ort of of plas plasti ticc to Va Vanc ncou ouve verr
-370 -3 704 4 btu btu disp displa lace ced d fuel fuel shi shipm pmen entt
1852 btu/l oil shipped to Yukon
7576 produce virgin plastic
1852 18 52 bt btu/ u/ll emp empty ty oi oill tru truck ck re retu turn rnin ing g sou south th
1852 18 52 tr tran ansp spor ortt new new pl plas asti ticc to to Yuk Yukon on as pr prod oduc ucts ts
1852 btu/kg transport recycled plastic to Yukon as products Total energy consumption:
Total energy consumption:
12,143 btu/kg
9,136 btu/kg
to recycle plastic and import fuel
to convert plastic to fuel and produce new plastic
T CO2 . . Recycling
Plastic to fuel
3.500 kg/kg plastic
0.186 kg/kg plastic
REMOTE ACCESS Fully operaonal remote monitoring and control of the B-240 was installed and tested. Full funconality has been obtained with the remote access. This was beyond what was expected, as we understood the remote access would be monitoring only and not actual operaon of the unit. The So Got soware and secure LogmeIn applicaon allow the machine funcons to be operated through a secure Internet connecon. This feature is coupled with an independently connected wireless security sec urity camera that allows crical components on the machine to be monitored visually.
RECOMMENDATIONS RECOMMENDA TIONS FOR REMOTE ACCESS
Install the remote-access feature as it allows greater ease in troubleshoong and supervision. Install more cameras, as they are inexpensive and easy to deploy/operate (i.e., 1 on load cell/extruder,, 1 on o take tank, 1 on conveyor hopper, cell/extruder hopper, and 1 in general area). The camera ulized allows for video recording to a memory me mory card as well as installaon of a speaker to enable 2-way communicaon between the operator and a remote supervisor.. This would allow low-skill operators supervisor operators to be compleng everyday tasks and a high-skilled supervisor to be overseeing the operaon on mulple machines
CONTAINERIZATION If the machine would be set up as a mobile unit in a trailer or container to travel between various communies, some changes would be required. Containerizaon of the machine would
Containerization
require some redesign of the components. The items that would need to be addressed and their corresponding soluons are as follows: Power supply
Issue: the need for an adequate power supply at remote sites
Soluon 1: install a 3-phase generator generator ulizing 30% of fuel produced (cost (cost of ~$18,000)
Soluon 2: install 2: install decontactor 3-phase, 200-amp plug (requires 3-phase power at each site; cost of ~$3000 to $20,000)
Glass glycol tubes
Issue: the fragile Pyrex glass could be damaged
Soluon: replace Pyrex glass with stainless steel and sight glass (cost of ~$0 if installed at Soluon: replace factory)
Glycol reservoir
Issue: loose-ng lid that is designed for staonary use; movement could result in spillage
Soluon: weld on spill-proof top and vent tube/ller cap (cost of ~$0 if installed at Soluon: weld factory)
Glycol chiller
Issue: loose-ng lid that is designed for staonary use; movement could result in spillage
Soluon: replace with closed-loop refrigeraon unit such as is used in commercial Soluon: replace refrigeratorss (cost of ~$4000) refrigerator
Load cell scale
Issue: sensive equipment
Soluon: remove Soluon: remove and secure during transport; recalibrate upon setup
Off take tank
Issue: full of fuel
Soluon: empty Soluon: empty before transport
Reactor and buffer tank hangers
Issue: transport could put strain on ngs
Soluon: add Soluon: add shock absorbers to limit lateral movement (cost of ~$400)
Levelling
Issue: machine designed to be operated on a level surface
Soluon: install Soluon: install levelling devices to container/trailer (cost of ~$9000)
Blest Plastic to Fuel
Molten plastic in reactor
Issue: splashing during transport
Soluon: add a sensor to lock levelling devices and lock brakes when reactor is above Soluon: add 75°C (plasc will be solid below this temperature); this will prevent movement of the system when it is unsafe to do so (cost of ~$5000)
Some of these modicaons could be ed on a new machine from the factory or retroed at a later date. All of the above modicaons are easy to implement. As the scalability of the machine allows operaon in small communies, it is recommended that rather than one mobile machine, several staonary machines should be ulized. This would reduce labour costs, as an operator does not need to travel with the machine. The operator of a mobile machine would need to stay in the area for day-to-day operaons, but these operaons only take 1 to 2 hours per day. If a local operator would be used, their work would be so infrequent that re-training would be necessary with every visit. Remote communies that are accessible by ship or road, but having no facilies with which to house the machine would benet from the unit being set up (all peripherals installed) in a shipping container so the operaon is turn-key and ready to operate at the install site.
COMMUNITY SIZE AND FEASIBILITY The naonal average for disposal of plasc is 58 kg per person per year year.. A producon analysis was esmated for Yukon communies and is summarized in the following table.
T Yk .
Community
Population
Average plastic recycling in kg per capita/annum*
Beaver Creek
1 00
5 80 0
26
Burwash Landing
90
5 22 0
24
Carmacks
51 9
30 102
1 36
Dawson City
201 0
116 580
116 (NVG 1000)
Carcross/Tagish
4 37
25 346
1 15
Faro
3 90
22 620
10 2
Haines Junction
8 64
50 112
228
Mayo
48 7
28 246
12 8
Old Crow
24 9
14 442
65
Pelly Crossing
34 8
20 184
92
Ross River
3 78
21 924
1 00
Teslin Tesl in
459
26 622
121
Watson Lake
1,495
86 710
36 5
Whitehorse
28,033
1 62 5 9 14
325 (NVG 5000)
Notes: NVG 220 sized unless otherwise stated NVG 1000 processes 1000 kg/day NVG 5000 processes 5000 kg/day
Days of production per community/annum
Factors Affecting Operations
A mobile version of the machine would be best mounted on a truck or a trailer unless it is desned for a barge-in/y-in community, community, where an install in an exisng warehouse or a container is recommended. The biggest challenges of mobile units are:
Having trained operators in each community, as well as keeping those trained operators current on the operaon of the machine when it is only needed in the community 15 to 20 days out of the year year.. However, However, this issue may be resolved by having supervision from a central locaon whereby instant communicaon to assist in operaons can be set up over secure Internet connecons. Keeping the feedstock consistent and within the accepted parameters. This will require careful sorng of the feedstock by facility sta.
POPULATION CONSIDERATIONS The Blest machine would be feasible to operate in a remote community with a populaon of 200 or more, unless there is another source of plasc such as beach clean-up operaons. This would provide a reasonable payback period on the machine as well as provide local employment and a local source of fuel. Addionally Addionally,, less waste will need to be dealt with through incineraon or landlling processes. The Return on Investment (ROI) is a simple calculaon, but does not take into account disposal costs as these vary by community community..
T ROI . Minimum days of operation per year*
Potential output of fuel (litres/year)
Size of machine
Value of fuel (@ $1.20/ litre)
Simple ROI (years)
20 0
52
11,600
NVG 220
$13,920
21.5
50 0
1 31
42,500
NVG 220
$51,000
5.88
10 00
263
85,000
NVG 220
$102,000
2.94
18 00
104
153,000
NVG 1000
$183,600
3.26
2,300
1 33
195,500
NVG 1000
$234,600
2.55
6,700
1 94
569,500
NVG 2000
$683,400
1.46
20000
232
1,700,000
NVG 5000
$2,040,000
0.98
Community population
* Assuming ~128 pounds plasc/person/year
FACTORS AFFECTING OPERATIONS Numerous factors associated with the operaons of the machine were observed and recorded. These factors are outlined below.
HUMIDITY OF FEEDSTOCK Humidity (moisture) levels in the feedstock can have an eect on the energy consumpon of the machine. This is due to the need for the moisture to be processed o the plasc during processing. Three sengs are available on the machine: N: for N: for up to 2% moisture
M: 2% M: 2% to 5%
H: 5% H: 5% to 10%
Blest Plastic to Fuel
Eight random samples of plasc were tested and found to have between 0% and 2.8% moisture content. Calibration for moisture
Proper calibraon was achieved with pre-programmed opons.
PLASTIC TYPES The Blest machine is designed to accept polypropylene, polyethylene and polystyrene types of plascs. These are beer known as #2, #4, #5 and #6 resin codes. Within these parameters, the Blest machine funconed as expected. Issues were idened when non-acceptable plasc types were processed. These included:
Nylon: The Nylon containing plascs, which is found in some brands of juice containers (#5 and #7 resin code) produced whish grease, which caused a buildup in the condenser.. This causes the machine to back up and stop producing fuel. condenser PETE: The PETE (found in #1 resin code) sublimates into a solid at temperatures below the operang temperatures of the machine. This accumulates as a grey semisolid material in the buer tank. When PETE is processed it produces 50% H2O that accumulates in the extruder as well as in the fuel. This eventually stops the machine from accepng plasc in the extruder extruder..
Calibration Calibra tion for plastic type ty pe
Within the normal range of feedstock encountered, the pre-set calibraons were adequate to process all of the acceptable plascs.
FUEL OUTPUT QUALITY The quality of fuel output can be opmized by various temperature adjustments as well as feedstock. Adjustments for fuel output quality
It was observed that at temperatures above 450°C, the fuel darkened considerably. considerably. This is due to the heavy oil components having a higher temperature needed for “cracking”. “cracking”. When the adjustments were kept at 430°C, the fuel output had a light, golden-yellow colour. colour.
FEEDSTOCK Proper sorng of the plasc is necessary in order to minimize downme with the machine. This includes removal of all PETE #1 and other #7 resins. Primarily we are targeng #4, #5 and #6 resins, as well as some #2 resins that are not accepted acce pted in the recycling markets (e.g., oil containers and pharmaceucal containers).
AMBIENT TE MPERA MPERATURES TURES A data logger was used to monitor ambient temperatures and correlate this to energy e nergy usage by the machine. It was expected that the energy usage would increase with decreases in ambient temperatures; however, however, this was found to have a minimal eect. At -1°C, we actually observed some of the highest eciencies at 0.89 kWh + 1 kg plasc to 1 litre fuel. Eciencies ranged from 0.89 kWh to 1.2 kWh/kg/litre
Troubleshooting/Repairs
Ambient temperatures temperatures encountered
The coldest temperature encountered in the facility was -1.76°C. The warmest temperature encountered was +26.9°C. Cold temperature operating guidelines Feedstock
To opmize producon in cold temperatures: 1. Ensure snow/ice is removed as much as possible from the plasc before before processing. processing. 2. If available, available, keep the plasc in a heated space to melt the ice/snow before processing. processing.
FUEL OUTPUT The unrened fuel generated by this machine will start to gel at -20°C. If ambient temperatures colder than 0°C are encountered in the area, a cold-weather opmizing kit is recommended by Blest. This involves the installaon of heang coils on the various parts of the o-take tank. These heang coils can be purchased locally and installed on site. Fuel output is maximized when proper feedstock is used in the machine. Shutdown S hutdown for maintenance is necessary when unacceptable resins are processed.
TROUBLESHOOTING/REPAIRS Some changes and modicaons were performed to enhance the operaon of the machine. These included:
Vibrator on the storage chamber: this chamber: this eliminated bridging problems that were encountered with some types of plascs.
Centre core on the screw auger: this facilitated transport of ne material.
Extruder feed cone: this cone: this facilitated processing of low specic gravity g ravity materials.
Reprogramming conveyor stops: this allowed the machine to turn o when the hopper was empty of plasc. Reprogramming scale stops: this allowed the machine to turn o in the t he event of a backup in the extruder.
Nitrogen purge valve: this reduced nitrogen consumpon during shutdown periods.
Condenser trap: this allowed easier cleaning of the condenser residues.
Deluxe o-gas lter: this lter: this reduced odours that were detected during start-up of the operaon. Pyrite gasses are reduced to 10 ppm from 50 ppm.
One item is sll to be installed:
Rheostat to slow feed auger: this auger: this would allow beer processing of low specic gravity materials. This part is currently being shipped from Japan.
Blest Plastic to Fuel
BIBLIOGRAPHY Bury,, D., 2011. Plascs Recovery in Canadian EPR. Plascs Recycling Update; hp://www. Bury duncanburyconsulng.ca/_documents/Plascs%20R duncanburycons ulng.ca/_documents/Plascs%20Recycling%20Update%20PRU_ ecycling%20Update%20PRU_ Feb11Bury.pdf ; [accessed November November,, 2013]. Government of Yukon, 2009. Communies. Government of Yuk Yukon; on; hp://www.gov.yk.ca/ aboutyukon/communies.html;; [accessed November aboutyukon/communies.html November,, 2013]. Guilford, G., 2013. A lot of US plasc isn’t actually being recycled since China put up its Green Fence. Quartz; hp://qz.com/122003/plasc-recycling-china-green-fence/#122003/plascrecycling-china-green-fence;; [accessed November recycling-china-green-fence November,, 2013]. Sheehan, J., Camobreco, V., V., Dueld, J., Graboski, M. and Shapouri, H., 2000. An Overview of Biodiesel and Petroleum Diesel Life Cycles. Naonal Energy Renewables Laboratory (NREL); hp://www.nrel.gov/docs/legos/fy98/24772.pdf ; [accessed November November,, 2013]. The Cambridge-MIT Instute, 2005. The ImpEE (Improving Engineering Educaon) Project: Recycling of Plascs. University of Cambridge; hp://www-g.eng.cam.ac.uk/impee/topics/ RecyclePlascs/les/Recycling%20Plasc%20v3%20PDF RecyclePlascs/les/Recy cling%20Plasc%20v3%20PDF.pdf .pdf ; [accessed November November,, 2013]. United States Environmental Protecon Agency (US EP EPA), A), Oce of Solid Waste and Emergency Response (OSWER), Oce of Resource Conservaon and Recovery, 2010. Waste Reducon Model. United States Environmental Protecon Agency (US EP EPA); A); hp://www.epa.gov/ climatechange/wycd/waste/downloads/plascs-chapter10-28-10.pdf ; [accessed November November,, 2013]. Yamashitak, K., Kumagai, K., Noguchi, M., Yamamoto, N., Ni, Y., Mizukoshi, A. and Yanagisawa, Y., 2007. VOC emissions from waste plascs during melng processes. The 6th Internaonal Conference on Indoor Air Quality Quality,, Venlaon & Energy Conservaon in Buildings, IAQVEC 2007, Oct. 28 - 31 2007, Sendai, Japan; hp://www.inive.org/members_area/medias/pdf/ Inive/IAQVEC2007/Yamashita.pdf ; [accessed November November,, 2013].
