GASIFICATION PLANT TO TRANSFORM PLASTICS INTO GASOLINE.

GASIFICATION PLANT TO TRANSFORM PLASTICS; It is an advanced technological facility that converts Plastic Waste into usable liquid fuels, such as Gasoline or Synthetic Diesel. This process can be part of a solution for plastic waste management and alternative fuel production. It has a slightly high initial cost, but it can be recovered with the recovery of waste and sale of fuels.

We will always respect all environmental regulations and strictly comply with local and global laws on emissions and waste.

MAIN CHARACTERISTICS

  1. It needs good separation and pretreatment of PLASTIC waste.
  2. Strict compliance with Environmental Standards (emissions, waste).
  3. Relatively new Technology.
  4. Compared to conventional recycling, it has more economic applicability.

MAIN COMPONENTS

  1. CRUSHER, DRYER:
    a. Feeding (Plastic) into fine particles (<100 μm).
    b.     Injection into the Reactor by means of Oxygen (O₂).
    c.     Equip
              I.Plastic Shredder Motor 30-50 HP
                        a. Steel Blades,
                        b.     Mesh <25 mm
              II. Rotary Dryer Capacity 6 TN/day, Indirect Heat

     

  2. GASIFICATION REACTOR (FLUIDIZED BED):a. Partial combustion with pure oxygen (O₂) or SIMPLE AIR. 
    b.     Dominant reactions:
              I. Oxidation: (C + frac {1}{2}O2 right arrow CO) 
              II. Reduction: (C + CO_2 right arrow 2 CO) (Boudouard)  
              III. Steam Gasification: (C + H2O right arrow CO + H2)
    c.     Equip
              I. Fluidized Bed Gasification Reactor, 5-8 t/day, Refracted Steel

     

  3. SCRUBBERS, CATALYTIC REACTORS:
    a. Rapid cooling to prevent gas recombination. 
    b. Removal of particles (filters or cyclones) and contaminants (H₂S, COS, HCl).
    c. Cleaning of SYNGAS CERAMIC FILTERS.
    d.     Equip
              I. Scrubber & Filter Particulate & Chlorine Removal

     

  4. FISCHER-TROPSCH REACTOR OR REFORMER:
    a. Conversion to Liquids.
    b.    The ashes melt at high temperatures, forming non-toxic vitrified slag.
    c.     Equip
              I.     FT High Pressure Reactor, Automated Safety System

     

  5. DISTILLATION TOWER:
    a. Steam generation for turbines or use in industrial processes.
    b.     Refinement.
    c.     Equip
              I.     Distillation Tower Separation of Hydrocarbon Fractions

     

  6. PLC PANELS, MONITORING:
    a. Control industrial processes.
    b.     Refinement.
    c.     Equip
              I.     Electric Generator (optional) Reuse Surplus Gas for Internal Energy

     

  7. STAINLESS STEEL TANKS:
    a. Storage Material liquid fuel.
    b.     Equip
              I.     Stainless Steel Tanks Store Liquid Fuel

ADVANTAGES

  1. A high purity SYNGAS (low in methane and tars).  
  2. Plant is suitable for CO₂ capture (PRE-COMBUSTION).  
  3. Integration with chemical processes (Fischer-Tropsch, hydrogen, ammonia).

CHALLENGES

  1. High cost of Oxygen, IF O₂ is used instead of RUNNING AIR.  
  2. It requires finely ground raw materials.  
  3. Sensitivity to fuel properties (Ash, Moisture).

APPLICATIONS

  1. Power generation (IGCC Combined Cycles).  
  2. Production of liquid fuels, such as Synthetic Diesel.  
  3. Manufacture of Hydrogen or Basic Chemicals.
  4. Production of Agricultural Fertilizers.

PROCESS OF A GASIFICATION PLANT TO TRANSFORM PLASTICS

  1. PLASTICS RECEPTION AND PREPARATION.
    a. Type of Raw Material: Plastic Waste PE, PP, PS, etc., is collected; PET and PVC should be avoided due to their chlorine (Cl) content and complicate the process due to the pollutants they generate (hydrochloric acid, for example).
    b.     Crushing and Drying:
              I.     Drying: Humidity is reduced to <5%.
              II.     Crushing and grinding: They are crushed and dried for easy handling and thermal reaction.).

     

  2. FEEDING THE GASIFIER FLUIDIZED BED
    a. Pressurized Feed System: Introduces dry powder to the reactor under high-pressure conditions.
    b.     Plastics are heated to high temperatures (800–1200 °C) in an environment with little or no oxygen, to avoid direct combustion.
    c. Plastic breaks down into syngas – SYNGAS: CO, H₂, Methane, etc.
    d.     The mixture: enters the reactor through special burners.

     

  3. GASIFICATION IN THE ENTRAINED FLOW REACTOR
    a. It occurs at high temperatures (1200–1600 °C) and pressures (up to 40 bar).
    b. The dust is carried away by the flow of the raising agent in a Flow-entrained.
    c.     Main reactions:
              I.     C + 1/2O₂ ⭢ CO (Partial Combustion)
              II.    C + H₂O ⭢ CO + H₂ (Gasification)
            III.     CO + H₂O ⭤  CO₂ + H₂ (Water-Gas Displacement Reaction)
              IV. A HOT GAS rich in H₂ and CO (syngas) is generated.

     

  4. COOLING AND CLEANING THE SYNGAS
    a. Impurities such as tars, acids, chlorine and particles are removed.
    b. This step is crucial to prevent damage to equipment and to produce HIGH quality fuels.
    c. Alkaline Scrubber + Ceramic Filter Absorption Column.
    d. Removal of HCI, Tars, Particulates, Heavy Metals
  5. FISCHER-TROPSCH REACTOR
    a. Clean gas is converted by SIMPLE processes into Liquids.
    b. Fischer-Tropsch (to obtain synthetic diesel and naphtha).

     

  6. LIQUID SEPARATION AND DISTILLATION
    Catalytic reforming and cracking (to adjust the composition of hydrocarbons towards Gasoline.

  7. VERTICAL TANKS FOR SYNTHETIC GASOLINE + BY PRODUCTS DIESEL, GASES
    a. With double wall or secondary containment and prevent leaks into the environment, in case of rupture of the primary tank.
    b.     The Protect the environment.
    c.     It can be made of stainless-steel fiber, higher corrosion resistance.
    d.     With a capacity of 10,000 liters.
    e.     Basic Components
         I.     Cylindrical steel body.
         II.     Flat or conical bottom.
         III.    Fixed or floating roof.
         IV.     Manhole, valves, sensors, level gauges, vents (vending).
         V.     Fire protection system (foam, water, sprinklers).
    f.     Advantages of Vertical Tanks.
         I.     Make better use of the space in the floor plan.
         II.     Facilitate drainage by gravity.
         III.     Lower evaporation compared to horizontal tanks.
         IV.     Increased capacity without taking up a lot of land.
    g.     Safety Considerations.
         I.     Fire suppression system.
         II.     Leak detection.
         III.     Grounding (atmospheric discharges).
         IV.     Vapor and pressure monitoring.
         V.     Secondary containment barriers (dikes or perimeter walls)

MAIN PROCESS

PROCESS RECEIVING AND PREPARING MSW (EQUIPMENT & FUNCTION)

  1. Receiving Hoppers
    Reception of Plastics.
  2. Shredders / Mills
    Reduction in material size (<100 μm) and clean up.
  3. Heat dryers
    Moisture removal (by hot air, steam or hot gases).
  4. Screw feeders and feeders
    Precise fuel feeding to the grinding or storage system.
  5. Storages
    Intermediate storage of dry and pulverized material.
  6. Inerting system (N₂ or CO₂)
    Prevents explosions in silos and dust transport lines.

REACTOR FEEDING SYSTEM (EQUIPMENT & FUNCTION)

  1. Double Airlock Valves / Rotary Valves
    Pressurized system isolation.
  2. Special injectors or burners
    They introduce the mixture of fuel + gasifying agent into the reactor.
  3. Mass flow dispensers
    They control the powder feed rate.
  4. Oxygen/air compressors or blowers
    They provide pressure and flow to the raising agent.

REACTOR (EQUIPMENT & FUNCTION)

  1. Cylindrical steel reactor with refractory lining
    Main area where thermochemical reactions occur.
  2. Instrumentation (thermocouples, pressure gauges, gas analyzers)
    Monitoring of pressure, temperature and composition of the gas.
  3. Slag chamber
    Collect molten slag that comes out by gravity.

SLAG MANAGEMENT (EQUIPMENT & FUNCTION)

  1. Slag coolers (quenching or exchanger)
    These solidify molten slag.
  2. Slag conveyor
    Remove the solid residue from the bottom of the reactor.
  3. Collection hoppers
    These store the slag for disposal or reuse.

SYNGAS COOLING (EQUIPMENT & FUNCTION)

  1.  Heat exchangers (shell & tube or gas-gas type)
    They recover energy from hot gas.
  2. Quench tower
    Lower the temperature of the syngas quickly using water.

GAS CLEANING SYSTEM (EQUIPMENT & FUNCTION)

  1. Cyclones
    Removal of coarse particles.
  2. Wet or dry scrubbers
    These remove acidic compounds (HCl, HF, SO₂).
  3. Ceramic or fabric filters
    These remove fine particles from the gas.
  4. Adsorbent bed reactors (ZnO, activated carbon, etc.)
    These remove H₂S, mercury, other contaminants.
  5. Compressors or blowers
    These transports and pressurizes clean syngas.

PROCESS WATER TREATMENT (EQUIPMENT & FUNCTION)

  1. Phase separators
    These remove oils or suspended solids.
  2. Chemical neutralization tanks
    These adjust pH and remove contaminants.
  3. Filters and reverse osmosis systems (if required)
    These purify water for recirculation or safe discharge.

USING THE SYNGAS (EQUIPMENT & FUNCTION)

  1. Gas turbines or engines
    Electricity generation.
  2. Fischer-Tropsch reactors
    Production of liquid fuels.
  3. Purificators PSA (Pressure Swing Adsorption)
    Production of pure Hydrogen.
  4. Industrial boilers or burners
    Thermal use of syngas.

SYSTEM AUXILIARY (EQUIPMENT & FUNCTION)

  1. Distributed Control System (DCS)
    Real-time automation and monitoring.
  2. Electrical System (Transformers, UPS)
    Power and energy backup.
  3. Fire safety and extinguishing systems
    Accident prevention.
  4. Ventilation and exhaust system
    Safety of the work environment.
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