DESC:
FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

Complete Specification
(See section 10 and rule 13)

1.Title of the Invention :

Catalytic Fuel oil Generating System (waste plastic and polymer waste)

2. Applicant Name : Altanol Technologies Pvt Ltd

Nationality : Indian

Address : Plot No.44P, 1st cross road
KIADB Industrial Area,
Nanjangud 571302, Mysore District

3. Preamble to the Description :

The following specification particularly describes the invention and the manner in which it is to be performed.

DESCRIPTION
Background of the invention
Waste management is an essential process that helps to make the world a better place to live. Reuse and recycling of waste products reduce the burden of management of huge quantum of waste generated by the modern cities. Waste products such as Cardboard, paper are easily recycled and are common. However waste plastic is very difficult to be recycled. This invention discloses a process and method of converting waste plastics to crude oil. The invention relates to a Catalytic Fuel Oil Generating system from waste plastic and polymer waste.
Description of the Invention
The process and method of converting waste plastic and polymer waste to fuel oil is disclosed here.
A preferred embodiment of the invention with respect to Fig 1 is detailed below :
10,000 Kg of Waste plastic and 100 Kg of catalyst (which comprises of 10 Kg of virgin material and 90 Kg of reuse material obtained from the previous batch process) are fed into a Blender/Mixer. This total 10,100 Kg of material is fed into the Blender/mixer.
The input material (waste plastic and catalyst) from the mixer is then fed into the Pyrolysis Reactor. The batch process is initiated with the use of the burner to increase the temperature gradually to the extent of 300 to 400°C. Gases begin to flow from the reactor to the condenser when the temperature exceeds 280°C. The gases flow through all three condensers and get condensed by the help of the cooling water from the cooling tower.
The condensed liquid output is pumped to the centrifuge. The material in the centrifuge is a mixture of water and oil. The centrifuge separates the oil and water and is collected in its respective outlets.
The final product/oil collected is 8200 Kg and is ready for packing. The water separated and collected from the final product is 350 Kg and is routed to the wet scrubber for cleaning purpose. Flue gas emitted from the reactor burner chamber is sent to the Air Heater. In this process, the hot air coming out of the air heater is routed to the gas burner that is used to heat up the reactor. On the other hand, the cold flue gas emitted is led to the wet scrubber for cleaning purpose. 25 Kg of Lime is added to the scrubber to bring down the pH level of the contents in the water. The clean water is then let out into the atmosphere, whereas 45 Kg of sludge is collected in the scrubbing process and is dried and packed for suitable disposal.
Similarly, during the process of condensation, the uncondensed gases/By product (about 1300 Kg) emitted out of the condensers are let to the gas storage. The gas storage has two outlets. The first outlet sends the required amount gas to the gas burner for heating purpose (the reactor). The second outlet, routes the excess gas which is 400 Kg to the power generator, in order to generate 50 KW power.
After the batch process/plastic pyrolysis comes to an end, the residue collected from the reactor is a mixture of charcoal, spent catalyst and ash (250 Kg). The Charcoal mixture residue burns in the Char Burner to release heat energy. The final residue collected from the Char Burner is 110 Kg. From that about 90 Kg is reused for the next batch process as spent catalyst and whereas the left over (20 Kg) is collected in bags for suitable disposal.
Description of Drawings
Fig. 1 : Process Flow Chart

Senthil Kumar B

Agent for the applicant
IN/PA-1549

,CLAIMS:CLAIMS

We claim:
1. A process for converting waste plastic and polymer waste into fuel oil, comprising,
a) feeding of waste plastic and catalyst into a blender / mixer
to prepare the input material for processing, such catalyst comprising about 10 percentage by weight of virgin material and 90 percentage by weight of reuse material obtained from a previous batch of processing,
b) feeding of such input material in to a Pyrolysis reactor,
c) initiation of batch process with the use of a burner to
increase the temperature gradually to the extent of about 300
to 400°C, resulting in the flow of gases from the reactor to the
condenser,
d) condensing of such gases in the condenser resulting in
condensed liquid output, which is a mixture of water and
fuel oil,
e) pumping of such condensed liquid output into a centrifuge,
wherein the fuel oil and water are separated and collected
from separate outlets,
f) passing of the hot flue gas emitted from the pyrolysis reactor
burner chamber to the Air heater resulting in the generation of
hot air and such hot air routed to the gas burner to heat up
the pyrolysis reactor,
g) passing of the cold flue gas to the wet scrubber for cleaning purpose,
h) adding of suitable quantity of Lime to the scrubber to bring down the pH level of the content in the water and letting out of such water and
i) drying, packing and disposal of the sludge collected in the scrubbing process.
2. The invention as claimed in claim1, wherein,
a) 10,000 Kg of waste plastic and 100 Kg of catalyst, such catalyst comprising of 10 Kg of virgin material and 90 Kg of reuse material obtained from the material obtained from the previous batch process, fed into the Blender / mixer, results in about 8200 Kg of fuel oil, about 350 Kg of water, about 45 Kg of sludge and about 1300 Kg of gas and about 110 Kg of final residue, and
b) wherein about 90 Kg of final residue is reused for the next batch process as spent catalyst.
3. A catalytic fuel oil generating system designed as per the invention
claimed in claim 1.

Senthil Kumar B
Agent for the applicant
(IN/PA-1549)