01 / Unique features
At the sites incoming waste will be processed immediately eliminating any stoppage; no need for huge storage areas and generating revenue from this point forward, process takes only seconds to 3 minutes tops and all this without emissions hurting the environment. Synthetic fossil-free fuel can be used in any engine designated to use Diesel; Kerosene or Naphtha or its Fuel Oil in boilers etc. without any modification to the original Engine new or old needed.
02 / Preparation Of Waste Input Material
The plastic film waste generated from the greenhouse industry in southern Spain is an ideal feedstock for CDP. The non-halogenated plastics offer a nearly ash free, chlorine free feedstock that does not require the expense of sorting associated with routine landfill waste. Plastic waste material is sent through our proprietary autoclave system where it is broken down to fluff. The dried material passes a fine shredder (Power Master) which reduces the particle size to <5 mm. This is the material suitable for the Fossil Free Fuel TM conversion process.
03 / De-polymerization of waste into high quality FOSSIL FREE FUEL TM
The shredded and dried input material is filled together with a catalyst and a neutralizing agent into the reactor vessel.
Heating to about 350° and heavy agitation starts the cracking process resulting in a mixture of oily hydrocarbons which, after reaching the required molecular size, turn into vapor which is conveyed into the distillation or rather condensation column. By fractional distillation, the various hydrocarbon fractions are separated into naphtha (a light gasoline-like fraction of crude oil), kerosene or jet-fuel, diesel and heavy oil.
Non condensable gases (methane) are used to feed a turbine which generates the electricity and thermal energy required or the process. The hot oil from the reactor vessel passes a filter press which eliminates any residues such as ash, remaining catalyst, sand, silicones, etc. This filter cake body, about 5-10% of original input volume, can be disposed of by adding it into an asphalt mixing process. Hence, the entire process is a true no-residue zero waste and zero emission technology.
It is expected that continuous high temperature centrifuge and sonic agglomeration will be the final key process elements allowing the CDP facility to achieve long periods of performance. Centrifuge has proven to be adequate for removal of solids including carbon black, feedstock ash, spent catalyst etc. Sonic agglomeration is expected to significantly reduce the loss of base oil due to aerosol transport from the reactor to the distillation column.