Unit 1 — CSTR System for Continuous Thermal Pyrolysis of Plastic Waste
The CSTR unit is designed to handle continuous plastic waste feedstock at a throughput of no less than 1 kg/hr, converting it into valuable liquid fuel and gaseous products through thermal cracking.
Reactor Vessel
- Stainless Steel 304, 4″ SCH10, length ≥ 1,500 mm
- 2 feed inlets, 1 gas outlet, 1 solid/liquid outlet
- ≥ 4 internal thermocouple transmitters
- Gauge and signal-transmitting pressure sensor + pressure relief device
- Internal stirrer with variable-speed motor (0–60 RPM)
- 3-zone electric furnace; max temperature ≥ 700 °C; heating rate 5–20 °C/min; computer-controlled
Screw Feeder System
- SS304 hopper, capacity ≥ 7 liters; sealed with sight glass, N₂ port, pressure relief, and anti-bridging agitator
- Feed rate: 0.5–1 kg/hr, computer-controlled
- Screw barrel heater: max ≥ 300 °C; cooling jacket near feed inlet
Nitrogen Gas Flow Control System
- Pressure regulator: 0–4 bar(g); 7-micron filter; solenoid valve with over-pressure interlock
- Mass flow controller: 0–1 L/min, computer-controlled
- Bypass purging line with rotameter: 1–10 L/min
- Non-return valve
Condensation & Liquid Collection System
- 2× SS304 shell-and-tube condensers with outlet temperature measurement
- 2× Double-jacketed SS304 liquid collection tanks, capacity ≥ 5 liters; with sight glass, level transmitter
- 2× Chillers, 5–20 °C, computer-controlled
- Total gas flow meter with signal output
- CO₂ sensor: 0–100%; H₂ sensor: 0–40,000 ppm
Control System
- PLC with Touchscreen HMI
- Independent control of temperature, stirring speed, and feed rate
- Real-time display, alarm system, and auto emergency shutdown
- Data logging; USB and Ethernet connectivity
Unit 2 — Fixed-Bed Reactor System for Gasification, Steam Reforming & Catalyst Regeneration
Reactor Assembly
- Stainless Steel 310S, 1.5″ SCH10 (OD 48.2 mm, wall 2.7 mm), length ≥ 700 mm
- 18-mesh internal support screen; 2 feed inlets, 1 outlet
- Internal thermocouple + pressure sensor (gauge & signal) + pressure relief device
- Outlet temperature transmitter
- 3-zone electric furnace; max temperature 1,000 °C; heating rate ≥ 20 °C/min; ≥ 800 W/zone; computer-controlled
CO₂ Gas Feed & Flow Control System
- CO₂ line heater; pressure regulator: 0–4 bar(g); 7-micron filter
- Solenoid valve with over-pressure interlock; signal-transmitting pressure sensor
- Mass flow controller: 0–2 L/min, computer-controlled; non-return valve
Steam Generation System
- Glass water reservoir, 500 mL
- 60-micron pre-filter
- Dosing pump: 0.5–10 mL/min, computer-controlled
- Steam generator heater: 100–200 °C, ≥ 500 W
- Trace heater along steam line (anti-condensation): 100–200 °C, ≥ 200 W
- Non-return valve
Condensation & Liquid Collection
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- SS304 shell-and-tube condenser; OD ≥ 35 mm, length ≥ 250 mm; outlet temperature measurement
- Glass liquid collection vessel, 1 liter
