LOW-TEMPERATURECATALYTIC DEPOLYMERIZATION

Power Generation from Plastic Waste,Tires and Waste Oils

Company Profile

The company GB Consulting s. r. o. delivers unique technologies introducing the concept of new and high standard for the secondary raw

material utilization in the field of renewable energy, using plastic waste, used tires and all types of waste polymers as the raw material input.

The company GB Consulting supplies low-temperature depolymerization technologies developed by the company Plasma Energy (P) Ltd. The final

product of the depolymerization technology, delivered by the company GB Pyrolysis Europe, is the production of the so-called “green” synthetic (fuel) oil

Poly-fuel®, carbon black Poly-carbon® and synthetic gas Poly-gas®. Moreover, tire treatment technology facilitates the recovery of steel.

GB Consulting with the support of RCFG*, constituting the part of the company Plasma Energy (P) Ltd., delivers

the technol-ogy for the synthetic oil processing, the outcome of which is patented fuel Polyfuel®, i.e. a hydrocarbon

liquid, composed of petrol, kerosene and diesel. Depolymerization technology is energetically self-sufficient and

for its operation uses the outlet raw materials. On the other hand, the technology can generate electrical power

and heat by the cogeneration (a combined generation of heat and electricity) and can exploit the waste polymers

ecologically and in a way providing the benefit in the form of the power generation. Otherwise, the disposal of the

waste polymers would be rather demanding, possibly harming and polluting the environment.

In consequence of global warming and large-scale utilization of all types of plastics, rubbers and used oils the waste recycling and its

conversion into another usable raw material is a very important step for the future of not only the Czech Republic, but the whole planet.

Depolymerization tech-nologies, delivered by GB Consulting, convert the polymer into fine raw material applying the process, which is

highly effective and environmentally friendly (completely ecological process) GB Consulting introduces the unique technology, which

can dramatically change the polymer waste manage-ment, currently prevailingly consisting of the pure and simple waste storage.

However, the polymer waste storage is nothing else than postponing the problem with the disposal to future generations. GB Consulting

launches the equipment onto the European market, which can tremendously help the environment.

GB Consulting put together a team of experienced and qualified experts in recycling,

power engineering, consultancy and marketing taking a considerable effort to produce

the energy from the wastes. Our professionals and technology suppliers are globally

recognized and operate in different countries all over the world.

Moreover, we are also active in the field of technological and waste heat exploitation and its tech-

nological conversion into the electrical power or chill. We furnish ORC technologies, absorption

cooling technologies, highly efficient gasifying units. We are involved in the energy management and

we are engaged in the complex savings of the electrical and heat power as well.

* RCFG – Research Centre for Fuel Generation Pyrolysis Systeme

We are pioneers and leaders in the manufacturing, deliveries and installations of depolymerization plants.We will provide complete turn-key solutions: machinery manufacturing, delivery, installation, commissioning, training.

Who we are, what we offer and deliver, benefits of our technology:

• our technology offers the purest quality of the synthetic oil comparable to the industrial diesel, selling pricecomparable to the industrial diesel LDO (light diesel oil)

• depolymerization process output is a cheap and high quality fuel as the substitution of diesel and LDO in the industrial production through long-term

research our research centre has developed own fuel Polyfuel®, i.e. a hydrocarbon liquid with the mixture of petrol, diesel and kerosene

• own patented technology - low-temperature catalytic depolymerization- reduces the reduction temperature (275 °C to max. 445 °C,

other technolo-gies functioning from > 550-650°C) and reaction time, the overall transformation process energy efficiency is

improved and, consequently, the profit-ability and power self-sufficiency of the overall production process are enhanced

• time-tested technology guarantees very high efficiency of the depolymerization process

• plants and processes proved by the installations already since the year 2004, results and experience from morethan 75 installed depolymerization plants all over the world and 25 years of the research experience

• we use “patent protected” catalyst, developed by our own research centre, improving the maximal efficiency of the entire

depolymerization process and facilitating the operation of the technology already from 275 °C to max. 445 °C (compared to

other technologies operating > 550 °C) with higher technological efficiency of produced fuel for more than 10 %

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• we assist in removing the heavy ecological burden by the landscape pollution

reduction, by considerable ecological disposal in the low temperature catalytic

depolymerization plant we reduce degradation of the plastic waste, used tire

waste, and we solve the prob-lem of the oil managements with the old used oil

disposal.

• we deliver maximally environmental friendly depoloymerization technologies

and pro-cesses, we widely use the waste-free technologies: without any

escape of carbon black, odor, harmful emissions, without any danger to the

plant staff health

• we use three safety levels preventing the fire break out

• we comply with all emission requirements, specified by the EU as the “Pollution Control Board”

• the operation of the depolymerization plant is energetically self-sufficient: no

other exter-nal energy is necessary to heat and operate the plant, which

considerably influences the economy of the operation and provides more

considerable economic return on invest-ment compared to other similar

technologies

• depolymerization technologies, delivered by our company, are

designed for continuous production process with the emphasis onsafety and profitability such as added value, without the risk ofexplosion

• fully automated process: no manual loading of carbon black or

intermediate products, technology solution reduces manpower

requirements

• daily input capacity of the continuous type of depolymerization plants from 1 to 25 tons of the polymer per day

• raw material flexibility: all types of polymers and oils can be used

• matter of fact is: PLC control, remote monitoring, sensor technology of the process monitoring

• complete turn-key solution: machinery production, delivery, installation, commissioning &1 week to 1 monthtraining at the site (depending on the size of technology)

Depolymerization Technology

The company GB Consulting delivers revolutionary technology using the processing of the waste plastic, oils and tires.

Development of depolymerization technology of the processing of the plastics, oils and tires includes:

• synthetic oil production - in the standard of the light diesel oil: completely transparent synthetic oil with the best quality

• development of more effective catalysts, shortening the reaction time and significantly reducing the reaction temperature compared to other technologies

• process transformation from the intermittent operation to the 3rd generation of the continuous type of the depolymerization plants

• advanced systems of the heat exchange, guaranteeing more profitable

• development of the electric generators, burning the synthetic oil

Waste plastics and tires are long-chain polymers, containing more than 50,000 carbon atoms, directly linked by the cross-link or branched chains. Depolymerization decomposes the long-chain to shorter chains - see below.

Thermochemical decomposition of the plastic or tire polymer

The co-operation between the company GB Consulting and the technology producer Plasma Energy (P) Ltd. resulted in the development of

commercially viable technology of the depolymerization of waste plastic, oils and tires, offering the following benefits:

• decreased reaction temperature from 275°C to max. 445°C (depending on the raw material type) with more than10% yield of the synthetic oil compared to other technologies)

• zero emission process: no harm to the environment

• reduced reaction time and substantial energy saving

• optimal conversion of the polymer waste to the hydrocarbonliquid with negligible wax content

• the latest scrubbing systems guaranteeing the sulphur contentin the synthetic oil less than 75 ppm

• patented - highly efficient process catalyst with very low costs for the production process

• continuous production process with less manpower and attendance staff requirements

• final product - synthetic oil - is very cheap and quality fuel

• perfect solution of the polymer waste management

• plant is energetically self-sufficient

• dimension and capacity of delivered lines from 1 ton to 25 tons of processed waste per day

Based on the research, carried-out for more than 25 years, the company Plasma Energy (P) Ltd. has successfully developed unique process

and production facility for the industrial low-temperature catalytic depolymerization of the polymer waste. Since 2004 we have been developing

depolym-erization plants in India, we have achieved phenomenal successes in the field of waste plastic, waste oil and tire depolymerization.

Process of Low-Temperature Catalytic Depolymerization

Depolymerization is the process of the molecular decomposition, larger moleculesare pyrolyzed to smaller molecules.

Depolymerization plant is an industrial facility for the waste plastic and tire processing. As regards the plastics/tires, the long-chain polymer is

decomposed into shorter chains of the synthetic gas and synthetic oil. Heat and catalyst are necessary for the subsequent reaction.

USED TIRES OR PLASTIC SYNTHETIC OIL SYNTHETIC GAS CARBON BLACK

USED OILS SYNTHETIC OIL

The technology does not burn the polymer waste; instead, the waste is decomposed into the usable final productssuch as synthetic oil, synthetic gas and carbon black.

Low-temperature catalytic depolymerization of plastics, oils and tires offers the following benefits:

• generates quality fuel with low emissions

• facilitates to solve the issue of the soil pollution with plastic, oils and tires

• recovers energy from the waste

• helps to recycle the carbon with its subsequent utilization

Depolymerization is the best available alternative for the waste oil and polymer management

compared to the incineration or dumping in the refuse storage area. The incineration means a

direct waste oxidation, leading to the loss of valuable energy from the polymer waste. The

polymer waste dumping in the refuse storage area results in the soil pollution.

Low-temperature catalytic depolymerization of the polymer waste helps us to recover a valu-

able energy from the waste in the form of the synthetic oil, synthetic gas and carbon black.

Process Flow Chart: Conversion of Waste Plastic (Tire) into Industrial Fuel

Process

Collection of waste Plastic

Transportat

ion of

waste

Plastic

to

factory

Shredding of Plastic

MaterialLoading

Plastic Melting

Plastic pyrolysis

Saperation of vapor phase

Cond

ensation

of

condens

able

fraction

Liquid and gassaperation

Filtratio

n and

purification of

synthetic oil

Storage of

syntheti

c oil

outside

building

Storage Of hydrocarbon Gas

Firing of

hydrocarbon

gas to heat

reactors,

scrubbing of

flue gas and

exhaust

Separation ofsolid phase

Equipment Name

Agglomerator

Loading Conveyor

Reactor Number:1

Reactor Number: 2& 3

Vapor Column

Condensors

Receivers

Filtration and purification system

Syntetic oil underground storage

Hydrocarbon Gas Storage Facility

Hot air generator, Suction

blowers, Scrubbing

system, Chimney

Car

bon

Bla

ck

rem

ova

l

and

coll

ecti

on

Sys

tem

Material Balance per 24 hrs*

10MT of waste plastic

10MTof shredded plastic

10MT of shredded plastic loaded in reactor

10MT ofplastic in molten form

10MT mixture of: Poly-

fuel® in

vapor form

+ Poly-

gas® +

Poly-

carbon®

8.5MT mixture of: Poly-

fuel® in

vapor

form +

Poly-gas®

8.5MT mixture of:

Poly-

fuel® in

Liquid

form +

Poly-

gas®

7MT of Poly-

fuel® Liquid at

bottom and

1.5MT of

hydrocarbon gas

at top

7MT of Filtered and purified Poly-fuel®

7MT of Poly-fuel® (Industrial Disel)

1.5MT of Poly-gas®

10,000Kcal/hr of

energy to run the

plant + Clean flue

gases that follows

Prevention &

Control of Pollution

Act

1.5MT of

Poly-

carbon® that is

used as

filler in

plastic,

rubber

and

tyre

recyclin

g

* Variable depending on quality of Raw material and catalyst

Depolymerization of Plastics, Tires and Waste OilsDepolymerization of plastics or tires is the process of the plastic waste and tire conversion into the synthetic oil, carbon black and synthetic gas.

Depolymerization plant converts the polymers into the fine fuel-plastics under controlled conditions and with the presence of the catalyst.

Depolymerization of Plastic, Oils & Tires: Input-Output Ratios

Input Material Input Quantity Output Quantity*

700 - 900 liters Poly-fuel®

Mixed plastic wastes 1,000 kg 50 - 100 kg Poly-gas®

30 - 50 kg Poly-carbon®

450 - 600 liters Poly-fuel®

Nylon tire waste 1,000 kg 100 - 120 Poly-gas®

250 - 350 kg Poly-carbon®

400 - 550 liters Poly-fuel®

Radial tire waste 1,000 kg 100 - 120 kg Poly-gas®

200 - 300 kg Poly-carbon®

80 -100 kg steel wire fine fragments

Motor oil and industrial oil waste 1,000 kg 900 - 1000 liters Poly-fuel®

* technology yield entirely depends on the type of the input waste and its composition

Various polymer waste materials are suitable as the raw materials. Below see the list of the plastic raw materials applicable to the depolymerization:

• waste plastic • waste tires

• electronic waste • rubber

• mixed plastics (HDPE, LDPE, PE, PP, nylon, Teflon, PS, ABS, FRP etc.) • plastic or rubber parts of the vehicles

• mixed waste from the waste paper recycling • waste engine oils, industrial oils, food industry and other oils etc.

• multi layered plastic

Resin Identification Codes

polyethylene high-density polyvinyl chloride low-density polypropylene polystyrene other plastics,terephthalate polyethylene polyethylene including acrylic,

polycarbonate,polyactic fibers,nylon, fiberglass

soft drink bottles, milk jugs, cleaning trays for sweets, crushed bottles, furniture, toys, hard packing, an example ofmineral water, fruit agents, laundry fruit, plastic packing shopping bags, consumers, refrigerator trays, one type is a

juice containers and detergents, bleaching (bubble foil) and highly-resistant luggage, toys as cosmetic bags, polycarbonate usedcooking oil agents, shampoo food foils to wrap sacks and most of well as bumpers, costume jewellery, for CD production

bottles, washing and the foodstuff the wrappings lining and external audio cassettes, CD and baby feedingshower soaps borders of the cars cases, vending cups bottles

Synthetic Oil Poly-fuel®

Our customers can produce the purest quality synthetic oil using the technology, which we manufacture and supply. Produced oil has the identical specifications as the light diesel oil (LDO). (*chemical analysis per request)

Typical industrial applications for the exploitation of Pyro-fuel® as the fuel:

• boilers burning LTO (central district heating plants, industrial boilers)

• diesel generators (cogeneration units)

• hot-water and steam generators

• hot-air generators

• thermic fluid heaters

• electric generators (mixed with 50% diesel)

• diesel pumps (mixed with 50% diesel)

Polyfuel® Synthetic Oil Usage:

• Electric power and heat generation (cogeneration), industrial processes, heating, vapour production

• Refining – production of diesel, petrol and kerosene

Electric Power Generation:

• Combusting synthetic oil in cogeneration units - CHP

• Conversion to electric energy with high efficiency of approx. 38 - 41,5%, heat efficiency 45 - 49%, Green Machine ORC modules for theutilization of heat

• Performance range from 80 kW to 3 000 kW

(Cogeneration unit suppliers: Caterpillar, Cummins, Perkins, Volvo)

Industrial Processes:

• Thermo-oil boilers

• Central heating, hot water production, vapour generation

Refining in Refineries:• Production - diesel, petroleum and kerosene - sale and distribution

Depolymerization Plant

Depolymerization plant is the technology converting the waste plastics, tires and waste oil into the syn-thetic oil, carbon black and pure synthetic gas.

The benefits of the depolymerization plants delivered by our company:

• the highest quality of the synthetic oil as the end product with guaranteed parameters

• use of “green technology” to guarantee environmentally friendly processes

• fully ecological process without any demands to the safety provisions

• plastics, tires as well as waste oils can be used as the raw materials

• continuous type of the low temperature depolymerization process

• breakthrough technology used to improve the safety,

profitability and facilitation of the operation

• more than 90% of the mechanical components are stationary,i.e. lower routine mainte-nance demands