A system for producing sustainable fuel from plastic waste from paper mills

Abstract

A system for producing sustainable fuel from paper mill plastic waste through pyrolysis, comprising: a waste collection unit configured to receive and store unsorted paper mill plastic waste; a pre-processing unit configured to prepare the paper mill plastic waste for pyrolysis, and comprising: a drying device that reduces the moisture content of the paper mill plastic waste; and a shredding device configured to reduce the paper mill plastic waste to particle sizes between 10 and 20 mm; a pyrolysis unit configured to thermochemically convert the pre-processed paper mill plastic waste at temperatures between 400-450°C in a low-oxygen environment;a product separation unit configured to separate pyrolysis products into a condensable vapor fraction, a non-condensable gas fraction, and a solid residue fraction; a condensation unit configured to condense the condensable vapor portion into pyro-oil; and a storage unit configured to store the pyro-oil, the non-condensable gas fraction, and the solid residue fraction.

Claims

[1] A system for producing sustainable fuel from plastic waste from a paper mill by pyrolysis, consisting of: a waste collection unit configured to receive and store unsorted plastic waste from paper mills; a pre-processing unit configured to prepare the plastic waste from the paper mill for pyrolysis, comprising: a drying device that reduces the moisture content of the plastic waste from the paper mill; and a shredding device configured to reduce plastic waste from the paper mill to particle sizes between 10 and 20 mm; a pyrolysis unit configured to thermochemically convert the pre-processed plastic waste from the paper mill at temperatures between 400-450 °C in a low-oxygen environment; a product separation unit configured to separate pyrolysis products into a condensable vapor fraction, a non-condensable gas fraction, and a solid residue fraction; a condensation unit configured to condense the condensable vapor portion into pyro oil; and a storage unit configured to store the pyro oil, the non-condensable gas fraction and the solid residue fraction. [2] The system of claim 1, wherein the waste collection unit is configured to receive plastic waste from paper mills comprising polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS) and polyvinyl chloride (PVC). [3] The system of claim 1, wherein the drying device comprises a sun drying platform configured to reduce the moisture content of the paper mill plastic waste from 40-55% to a level suitable for pyrolysis. [4] The system of claim 1, wherein the pyrolysis unit comprises: a sealed reactor chamber configured to maintain low-oxygen conditions; a heating system that maintains the temperature between 400 and 450 °C; and a control system configured to monitor and regulate the temperature throughout the pyrolysis process. [5] The system of claim 1, wherein the condensation unit is configured to produce pyro oil having a density lower than water, a viscosity higher than commercial fuels, a flash point classifying it as a flammable liquid, and a heating value suitable for use as a fuel. [6] The system of claim 1, further comprising a gas recovery unit configured to collect and process the non-condensable gas portion for use as auxiliary fuel in the pyrolysis operation of the system. [7] The system of claim 1, further comprising a charcoal processing unit configured to process the solid residue fraction for applications such as the production of activated carbon and as additives in building materials. [8] The system of claim 1, further comprising an analysis unit configured to test and validate the physicochemical properties of the pyro oil, including density, viscosity, calorific value, cloud point, pour point, flash point and fire point. [9] The system of claim 1, wherein the system is configured to deliver pyro oil in a range of 42-56% of the total power, gaseous products in a range of 14-23% of the total power, and pyro coal in a range of 22-34% of the total power. [10] The system of claim 1, further comprising a fuel blending unit configured to blend the produced pyro oil with other fuels to meet certain fuel standards and requirements.

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