PUR/3/26-27/400691/AM/UWRD

Continuous Trial Study for Plastic Pyrolysis (1 kg/h Feed Capacity) on Pilot Scale Auger Reactor Continuous Trial Study for Plastic Pyrolysis (1 kg/h Feed Capacity) on Pilot Scale Auger Reactor 1. Objective To evaluate and compare the performance of two auger reactor configurations for continuous plastic pyrolysis at pilot scale, through controlled 36–48 hr continuous trials, generating comprehensive datasets for material balance, energy balance, and product characterization. 2. Reactor Configurations • Type 1: Auger Reactor with Axial mixing equipped with continuous residue (coke) removal mechanism. 2. • Type 2: Auger Reactor with both Axial and radial mixing equipped with continuous residue (coke) removal mechanism. Both systems must be designed for continuous operation with robust feed handling, residue discharge, and product recovery subsystems. System should be free from oxygen. 3. Operating Parameters • Plastic Feed Rate: 1 kg/h (continuous, steadystate) • Reactor Operating Temperature: 650 °C (± 5 °C control band) • Material of Construction (MOC): o Compatible with cracked hydrocarbons and molten plastics. o Corrosion resistance against halogenated species and thermal degradation products. • Continuous Trial Duration: Minimum 36–48 hrs per configuration per trial. • Total Service (trial) Period: 10 days (5 days for Type 1 reactor configuration and 5 days for Type 2 reactor configuration). 4. Product Handling & Preservation • Gas Phase: Collected in calibrated gas holders, analyzed for composition, calorific value, and impurities. • Liquid Phase: Condensed via staged quench/condensation system, stored in inert lined containers, preserved for CSIR IIP Dehradun testing. • Residue/Char: Continuously removed, weighed, and preserved for further analysis. • Coke and liquid product should be transported at CSIR-IIP, Dehradun and this scope under SEPREX PVT. Ltd, Pune 5. Trial Execution & Documentation • Standard Operating Procedure (SOP): o Detailed stepwise procedure covering feeding, reactor startup, steady state operation, sampling, shutdown, and safety protocols. o SOP must be executed and signed off during trial runs. • Data Logging: o Raw and processed trial data logs (temperature profiles, feed rates, product yields, energy consumption, downtime events). o Time stamped operator logs for every 30 minute interval. • Material Balance Sheets: o Input vs. output reconciliation (mass closure ≥ 95%). o Separate balances for gas, liquid, and residue fractions. • Energy Balance Sheets: o Reactor heat duty, auxiliary power consumption, energy recovery efficiency. o Specific energy consumption per kg of plastic feed. • Design input of both type 1 and type 2 reactors to be provided to CSIR-IIP 6. Deliverables 1. Comprehensive SOP Document (executed during trials). 2. Material Balance Sheets for each configuration. 3. Energy Balance Sheets for each configuration. 4. Complete Trial Data Logs (raw + processed). 5. Preserved Product Samples (gas, liquid, residue) delivered to CSIR IIP Dehradun. 6. Comparative Performance Report recommending the optimal reactor configuration based on yield distribution, energy efficiency, and operational stability. 10NO