APC's Patented Pyrolysis Technology

APChemi has developed patent-pending waste-to-energy technologies for chemical recycling of the toughest and dirtiest plastics including municipal solid waste segregated plastics and multilayer packaging. Mentioned above is the process flow chart of APChemi Technology and given below is the process description:

(1) Polymer waste is stored in a raw material storage facility. This raw material is then conveyed to (2) airlock feeding system which feeds the raw material into the (3) Pyrolysis reactor in absence of oxygen. Pyrolysis reactor converts polymer waste into pyrolysis oil vapour, hydrocarbon gas and carbon black powder. (4) Carbon black powder is cooled and packed into 1000kilogram bags for sale. (5) The mixture of pyrolysis oil vapour and hydrocarbon gas exits pyrolysis reactor and is subjected to (6) fractional condensation so as to get separate fractions of (7) hydrocarbon gas (10) pyrolysis wax and ‘pyrolysis oil + Moisture’. Hydrocarbon gas is subjected to (8) high-temperature combustion and the energy produced is supplied to the pyrolysis reactor. Post high-temperature combustion, the exhaust gases are subjected to ‘waste heat recovery and scrubbing to control emission’ and cleaned flue gases are passed to (9) exhaust pipe. (10) Pyrolysis wax is either subjected to (8) high-temperature combustion or is refined into (11) base oil for grease manufacturing. (11) the base oil is then converted into (12) lubricating grease and oils.  The mixture of ‘pyrolysis oil + Moisture’ is passed through (13) oil-water separator to separate (14) the Pyrolysis oil from (21) Oily Wastewater. (21) Oily Wastewater is passed through (22) Water-oil separator to separate (24) oily sludge which goes back to the pyrolysis reactor as raw material and wastewater for incineration/effluent treatment (23). (14) Pyrolysis oil can be sold as it is in the market as a liquid fuel to be used in industrial burners.  Otherwise, (14) Pyrolysis oil is either burned in slow-speed engines to produce (15) electricity or is (16) refined into petroleum products like (17) Kerosene, (18) Diesel, Base Oil (19) & Heavy Fuel Oil (20).

APChemi has proven and operational pyrolysis technology. In the same reactor, you can process waste plastic, tyres, waste oils, greases, biomass, lube oils, etc. Given below are the 3 pillars of our approach to technology development:

1) Safety First

 

During the pyrolysis process, plastic is heated to an explosive temperature, leakage of air inside the reactor can create the hazard. We at APChemi are committed to safety by ensuring compliance with latest practices in process safety as well as metallurgy. Unlike the most, we do not heat reactor by direct flame.

APChemi is keenly interested in technology licensing for promoting sustainable recycling of waste plastic and waste lubricants.

2) Energy Efficiency

 

The energy efficiency of the plant decides the profitability of the pyrolysis operation. Energy recovery is an integral part of APChemi's Pyrolysis Plant. Highly energy efficient Pyrolysis Reactor designed by APChemi ensures maximum pyrolysis efficiency at the lowest possible temperature and heat load.

Flexibility

3) Feedstock Flexibility

 

APChemi's pyrolysis plant can process solids, semisolids, waxes, and liquids. You can process plastic, tire, biomass and waste oils - all in the same reactor. You can feed high-density raw material and low-density raw material. We understand that technology needs to be agile so as to accommodate variations in feedstock composition

Further Reading:

  • What is Pyrolysis?

  • Pyrolysis Plant

  • Plastic Pyrolysis

  • Tire Pyrolysis

  • Biomass Pyrolysis