What are the preferred feed stocks for the unit?

All waste and organic materials in general are preferred feed stocks for the unit. The list is vast but few examples as below:

  • Plastics (Any kind)
  • Vegetable Oil
  • Animal Fat
  • Petroleum by products / Sludge / Wax
  • Used Motor Oil / Rubber Tires
  • Sewage Waste
  • Jathropha Fruits
  • Palm Fruit Waste
  • Sludge from Edible Oil Industry
  • De-oiled Cake from Edible Oil Industry
  • Bamboo (Gasification only)
  • Wood Chips (Gasification only)
  • Other Organic Matters which contain Lipids

What is the conversion ratio of different plastic feed stocks?

The conversion ratio is input specific. HDPE, LDPE, PP will yield highest yields of approximate 1 kg to 1.1 liters. Other plastics will have reduced yields and may yield approximately 800 ml per kg. PET not to be used, as PET will have a higher commercial value as a recyclable material. PVC will have the lowest yield of approximately 300 ml per kg.

What kind of yields can be expected from processing waste plastics in the unit?

The yield is proportionate to the quality of plastic.
Although, the expected yield is 1.1 liter of fuel per Kg of plastic, hence 25 tons of plastic waste could generate upto 27,500 liters of fuel.

Is sizing required for feed stock? What size of feedstock is necessary?

Yes, the feedstocks need to be sized, preferably to 2.5 inches.

Do the feedstocks need to be assorted / sorted?

No, the feedstocks are not required to be assorted/sorted. A mix of feedstocks can be fed in the unit for processing.

What is the size (H/W/L) of each unit module?

Specifications would be subject to per day required processing capacity of the machine.

What is the area required for feedstock storage and pre-processing / pretreatment?

The area required for feedstock storage depends on the waste generated/collected on daily basis for processing.

What are the products and by-products of the process?

The product and by-products of the process are on the basis of the feedstocks, in general the following products and by- products are produced/generated:

  • Liquid fuel
  • Liquefied petroleum gas
  • Petroleum Coke / carbon residue
  • Water

What is the level of automation?

The unit is highly automated with process controllers controlling the operations.

How many days of feed stock are needed in back stock?

Although waste is generated every day, we suggest 7 days of feedstock to be stocked, if required. Not required for captive users.

What is the tolerance in quality of feed stock?

Highly tolerable to moisture and contamination. Process can handle wet plastics having moisture up to 40% and organic contaminants. In the mixed feed stock, up to 5% PVC is tolerable.

Are there any operational units?

Yes, there are units which are currently in operation.
We have a demo unit in Wada, close to Mumbai. We also have demo units in Italy, Netherlands, USA & Malaysia.

What is the energy efficiency of the unit?

The unit does require minimum electrical power to run the pumps, motors, automation, and plant lighting.
Out of the output gas from the unit approximately 80 - 82% will be used to energize the unit.

What is the ideal temperature for the process?

The ideal temperature is around 360oC to 450oC.

Is a catalyst used during the process?

Yes, a proprietary multifunctional catalyst is used during the process.
The patent for the same is applied for and is pending.

What is the number of Multifunctional catalyst (MFC) needed for each liter of fuel conversion?

Catalyst is supplied in the form of field replaceable cartridges.
The cartridges will be required to change as and when they are consumed and contaminated.

What is the price of MFC catalyst?

The catalyst is not sold. The catalyst is supplied as a part of the licensing agreement.
Unlimited supply of MFC catalyst as required to process the plastics will be provided.
The charges are based on per ton of plastic/raw material processed.

Is the unit portable?

Each unit upto one ton capacity is portable and can be moved/relocated to another location easily.

Is the final product (fuels) analyzed?

The final products (fuels) have been analyzed in third party laboratory and the certification can be provided on request.

Is there any certification required from appropriate authorities?

No, the fuels are not being projected as motor fuels and hence certification from authorities is not required.

Where are these fuels used?

The fuels have varied usage, like to fire furnaces, run generators sets and in engines of sea going vessels.

Is further processing of fuels necessary?

The further processing of fuels is only necessary depending on the usage.
The fuels need to be refined if required to convert it to petrol, kerosene or diesel.
The fuel output as is basis can be used for stationery engines and in case the same has to be converted to motor fuels then additional equipment is required, viz., Distillation column and de-sulphurization unit.

What are the certificates that are required for selling final products in market?

No certification required if the fuels are used in boiler, furnace and generator sets.
However, licensing from local authorities for sale etc. may be needed as these requirements vary from place to place and are country specified. Local requirements have to be studied and necessary permits obtained based on the location of the site where the unit is installed.

Where is our corporate office located?

UK - 123 Ffordd - Y - Draen, Coity, Bridgend, Wales, CF356FQ, UK
India - 244, Kuber complex, new link road, Andheri west Mumbai – 400053, Maharashtra, India.

For processing the order we would require the following information to proceed:

Company Name:
Contact Person:
Mobile No.:
Site Location/Address:
Type of the Feedstock (content details):
Quantity Available (on daily basis):
Required daily Processing Capacity of Unit:
Application: Compliance, Resource Recovery/Waste Disposal
Area available for installation of Unit (in sq ft):
Electricity (Power Details): Ph/ voltage/amp/Hz
Interest: End user/Representative/Academic/ Business.
Please send mail with the above details to nitin@polycrack.com

Where is the demo unit installed? Can we visit and see the demo unit?

We have installed a demo unit in Wada, which is 110 kms by road from Mumbai on the Western Express Highway. Yes, either you or a company representative can visit the site where the demo unit is installed.
We can also process a specific feedstock provided, the entire process can be viewed. The products/by-products generated can be taken for testing in a third party laboratory at your sole discretion.

What is the warranty/guarantee on parts used in unit?

We offer warranty on workmanship and free replacement of defective parts for a period of one year.
Our on-site supervisor will operate the unit for a period of 3 months prior to final hand over. During this period, the unit capacities will be proved and unit parameters adjusted to maximize yield from specific feedstock.

How hard is it to operate the unit and are they maintenance intensive?

It is not very difficult to operate the unit, a SOP on operation will be provided on installation of the unit.
The unit is not maintenance intensive but we advise regular maintenance to be done on a monthly basis.
The unit needs a complete shutdown to clean reactors; this is one of the most important steps of unit maintenance.
The catalytic convertors are outside the process reactors and the catalysts have to be replaced depending on the indicator.

The catalyst change does not require shut down of the reactors and the catalyst can be changed while the process is on.

After order what is the lead time for delivery of unit?

The delivery lead time will depend on the size of the machine and can vary from 2 months to 6 months from the date of receipt of advance payment.

The unit will be tested prior to shipment and hence least time is required for erection and commissioning of unit at site.

What is the guarantee on the output products of unit?

The product output depends upon the quality and mix of the input (feedstock).

What are the training requirements for engineers/operators?

Engineers/Operators will be provided on site training for a period of 3 months. Additionally, Operation Manual, Maintenance Manual and Safety Manual will be provided on delivery of the unit.

What are the environmental requirements, such as permits and licenses (EPA)?

The entire process is designed to function in a Closed Loop System so that the emission parameters are met easily. This unit is a zero discharge unit and therefore no air, water or other pollution.

Does Polycrack system accept PVC?

Polycrack can process any waste but can only tolerate up to 5% PVC in the feedstock.

What are the Polycrack advantages in comparison to the other technologies?

One major area where most of the plastic-to-fuel technologies fail compared to Polycrack is the quality of fuel produced. All such technologies use a catalyst, typically metallic oxides or aluminum silicate compounds to convert the plastic to fuel. However, the fuel produced has high traces of catalyst, almost 2% to 5% residue (approximately 500 Kg to 1250 Kg) in a 25 Ton per day unit. This high volume of residue created is one reason why most plastic-to-fuel conversion units do not get environmental clearances as the residue has to be disposed. Additionally the residue is not environmental friendly.

Our process leaves no catalyst in the residues. The residue is free carbon that can be compressed into pellets and used as fuel in furnaces. A unit with capacity of 25 Tons a day using our technology would typically produce residue of about 1 ton of free flowing carbon powder which has commercial value.

Our process can handle moist & dirty plastic, mixed plastic and industrial plastic including automobile fluff.
Our process can handle mixed feedstock like plastic along with biomass, waste oil, refinery sludge etc. We can practically run all kinds of plastics including the metalized ones, plastics backed with aluminum foils, tetrapacks etc. The yields however will vary depending upon the polymer content in the input material.

The presence of metals, glass, fiber, wire, cable, organic, inorganic, TiO2 fillers etc. does not impact the process in the unit.