Surprisingly, furnace oil can be produced from waste plastic through a process that has been around since ancient times called pyrolysis.
That furnace oil can be created from waste plastic might sound like magic but it’s just good science.
Wikipedia defines pyrolysis as “a process involving the separation of covalent bonds in organic matter by thermal decomposition within an inert environment without oxygen.”
The technical verbiage for how the process works:
A decomposition process of long-chain hydrocarbon (polymer) molecules into smaller sizes (monomer) with the use of high heat, controlled pressure and with a shorter retention time in the process. Some percentage of resulting volatiles from the reaction may be condensed into liquid fuel at room temperature (Mixture of compounds containing C2 to C25). A smaller percentage would be non-condensable gas with the rest is residue (generally unusable).
In laymen terms it, basically, means that the plastic is melted at high temperature and under pressure and the results are separated into gases and other things (which is generally waste byproducts including wax). Some of those gases can be condensed into a liquid that is an oil.
While we applaud the other companies who turn plastic into reusable products we found the efficiency of their process and their results disappointing.
So, our team decided to improve on those results and they were so exceptionally successful and unique that we were able to get an International Patent.
Not only were we able to get a higher percentage of quality fuel (80-85%) than others, we were able to use the resultant gases (10-12%) to fuel our pyrolysis process (saving us time and money) and produced very minimal waste including zero wax unlike others who produce up to 30% wax. We also were able to have zero emissions from our process so there is no environmental impact.
Here is a high level overview of our process:
- Get waste plastic from municipalities and other organizations
- Melt it under carefully controlled high heat and pressure for a short time; this is critical to maximize results and avoid explosions
- Condense a large majority (80-85%) of the gas at room temperature into liquid fuel
- Reroute the non-condensable gas (10-12%) to fuel this process
- Separate any residue to be used elsewhere; with no waste wax that interrupts the process to be cleaned out from the equipment
Why This is a Better Way
There are a number of reasons we are proud of what we’ve developed and consider it superior.
- Of course, the main reason is that we are able to convert tons of waste plastic into a good quality of furnace fuel. Removing plastic from the waste stream while generating fuel without the need for drilling and refining.
- Our process is very efficient, more so than was previously possible.
- Our process generates no wax in the process and our systems don’t need to stop to clean the out the waste wax.
- Our process is able to fuel itself with the gas that can’t be converted into fuel; this gives us a large cost saving.
- Our process releases no emissions
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