Title: An energy evaluation for thermal conversion of thermoplastic waste to refined oil products using pyrolysis reaction process system

Authors: Hossam A. Gabbar; Mohamed Aboughaly; Awais Choudhary

Addresses: Faculty of Energy Systems and Nuclear Science, University of Ontario Institute of Technology, 2000 Simcoe Street North, Oshawa, L1H 7K4 ON, Canada ' Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, 2000 Simcoe Street North, Oshawa, L1H 7K4 ON, Canada ' Faculty of Engineering and Applied Science, University of Ontario Institute of Technology, 2000 Simcoe Street North, Oshawa, L1H 7K4 ON, Canada

Abstract: Thermoplastics are converted to hydrocarbon fuels in a chemical reaction called pyrolysis. The work highlights the energy consumption using Aspen HYSYSV8.8 simulations in each process stage starting with granulation, preheating, pyrolysis reactor and condensation as major process steps concluding that the highest required heat duty which is around 61% in the pyrolysis reactor thus having the highest operating cost. Aspen HYSYS is used to calculate energy consumption in each stage. The design is 10 tonne/hour of thermoplastic mixture. Pyrolys is reactor operating temperatures are 550°C at atmospheric pressure. The condensation system shows recovery duty of 3.4 MW of which can be used to heat cold streams. Pinch analysis was also carried out to design a heat exchanger network (HEN) between hot and cold streams in order to reduce energy consumption. Heat recovery from pyrolysis reactor effluent gases shows possible 3.439 MW recovery in a 10 tonne per hour pyrolysis plant.

Keywords: sustainable process design; thermoplastics; oil production; hydrocarbon fuels; energy consumption; simulation; mass and energy balance; pyrolysis reactors; hydrocarbon liquids; char; heat recovery; reactor effluent gases; sustainability; cyclohexane; methane; pinch analysis; heat exchange networks; thermal conversion; thermoplastic waste; refined oil products.

DOI: 10.1504/IJPSE.2016.081208

International Journal of Process Systems Engineering, 2016 Vol.4 No.1, pp.65 - 79

Received: 17 Aug 2016
Accepted: 12 Oct 2016
Published online: 27 Dec 2016 *