Plastic2Oil (P2O) Technology

Reputable independent labs have validated the P2O technology including IsleChem (process engineering) and Conestoga-Rovers & Associates (emissions stack test). Plastic2Oil has been issued all necessary permits to operate by the New York State Department of Environmental Conservation (NYSDEC). Engineering report performed by SAIC validates and verifies the technology and economics.

The processor requires only 4,500 sq. ft. of operating space. Height requirement is approximately 20 ft. Highly automated; very low operator to processor ratio. Modular design allows for easy deployment.

The P2O processor accepts unwashed, unsorted waste plastics. Optimal feedstocks include polyethylene and polypropylene. The P2O process is permitted by the NYSDEC for up to 4,000 lbs. of plastic feedstock per machine per hour at the Company`s Niagara Falls, NY facility.

The conversion ratio for waste plastic into fuel averages 86%. Approximately 1 gallon of fuel is extracted from 8.3 lbs. of plastic. The processor uses its own off-gases as fuel (approximately 10-12% of process output); minimal energy is required to run the machine. Approximately 2-4% of the resulting product is Petcoke (Carbon Black), a high BTU fuel. Emissions are lower than a natural gas furnace of similar size, and the quality of the emissions improve with increased feed rates. Results from the final stack test performed by Conestoga-Rivers & Associates confirm that the processor emissions are well within the limits allowable under a NYSDEC air permit. The process operates at atmospheric pressure, and is not susceptible to pinhole leaks and/or other problems with other pressure and vacuum-based systems. The reusable catalyst is produced economically. The fuel produced is refined and separated without the high cost of a distillation tower.

The P2O processor is designed to use minimal amounts of external energy. As well as being beneficial for the environment, this is also a significant factor in the commercial viability of the process. Water is used for cooling only and usage is minimized through recycling the water in a non-contact closed loop. The water is not in contact with the process itself, keeping it clean and uncontaminated. Only 53 kWh electricity is required to run the fans, pumps and small motors. No electricity is used in the transformation of the plastic to fuel. Natural gas is only used on start-up to heat the reactor – once the processor is running, the reactor is heated with its own off-gases. A facility-wide gas compression system governs natural gas usage throughout the entire production process.

Fuel quality has been validated by multiple independent petro-chemical labs including: Intertek, PetroLabs, Alberta Resource Council and Southwest Research Institute. All shipments leaving the P2O plant in Niagara Falls are tested by the Company`s fully equipped internal fuel testing lab. Fuel is ready for sale upon completion of processing without the need for further refinement. From a single processor the Company can produce a range of fuel products, without further refining, including No. 2 Fuel (Diesel, Petroleum Distillate), No. 6 Fuel, Naphtha, Petcoke (Carbon Black), and Off-Gases to be used in the P2O process.

Plastic2Oil`s P2O processor has evolved significantly since inception. In its current configuration, the processor requires approximately 4,500 sq. ft. to operate which makes it ideal for local site installations. General operations involve monitoring the control room screens and cameras to track each processor`s operating parameters, as well as loading plastic onto the in-feed system.

The processor accepts unwashed, unsorted waste plastics, composites and commingled materials.

Although many sources of feedstock are available, we are focusing initially on post-commercial and industrial sources, since these are readily available in large supply, and present a cost-effective solution for companies. 

The hopper can be loaded with up to 4,000 lbs. of plastic feedstock per machine per hour using a forklift. The plastic is loaded into the pre-melt reactor by a continuous conveyor between the hopper and the reactor. The plastic is then heated using the off-gases produced by the process.

After the plastic has been liquified in the pre-melt reactor it passes through a solids-liquids separator before going into the main reactor. 

In the main reactor, the liquified plastic hydrocarbons are cracked into various shorter hydrocarbon chains and exit in a gaseous state.

Plastic2Oil`s proprietary catalyst and unique process engineering enables us to capture an average of 86% of the hydrocarbon content of plastic.

The Petcoke residue produced at this stage (approx. 2-4%) remains in the processor chamber and is automatically removed while the processor is in operation.  

From the main reactor, the gases that are fuel oil and diesel are condensed and separated, then proceed into temporary fuel tanks. All of the gaseous "light fractions" or off-gases (approx. 10-12% of process output), such as methane, ethane, butane and propane, exit the system and are used to fuel the furnaces.

The fuel output is transferred to additional tanks for storage automatically by the system. Our automation system controls the conveyor feed rate, manages system temperatures and the off-gas compression systems, as well as periodically pumping out the newly created fuel to storage tanks. The P2O process is `closed-loop`. 

Significant technological advantages have been integrated to downstream operations to guarantee fuel quality, along with installing an inline fuel additive injection system on both heavy and light fuel condensing systems. We have also engineered a hot-tap residue removal process. 

Quality control includes two columns for control and specificity of fuel fractions, a cyclone (particulate removal in vapor), fuel filters (particulate removal in liquid), and a centrifuge (additional redundant particulate trap), as well as column enhancements to guarantee particulate free fuel.

Fuel additives are injected inline while fuel is being produced to increase their effectiveness. The residue removal system works while the processor is running; the reactor does not have to be cooled down or stopped to remove residue. 

The Company created a modular design and standardized the system to racked reactors, feeders and towers. This reduced the system footprint to a few unique modules, making fabrication and installation for deployment simpler. 

Over the years, upgrades have included the installation of low NOx burners and the addition of a pre-melt system to increase through-put volumes. The Company has worked with third party fabricators to produce standardized reactors and towers. 

A cyclone is used in the second machine to help remove particulate matter in the vapor stream. 

Many of the P2O process variations are unique to Plastic2Oil and the Company has filed for international patent protection.

The Company will continue to seek patent protection on subsequent innovations as they are developed and require protecting.