About the technology
IKHLYAS TECHNOLOGY has developed a safe way to completely recycle plastic waste into useful, ready-to-use, and most importantly, environmentally-sustainable products, without polluting the environment.
Stage 1. The preparation of polymer waste
Waste plastics can be divided into the categories in the graph, with an approximate percentage of the total weight. 40-70% of all polymer waste can be used as raw materials for the plant.
Polymer waste which is not suitable for recycling, such as packaging, bags, and other polymeric waste, is usually buried in solid household-waste landfills. The IKHTECH Unit’s potential for environmental protection is extensive — including reducing landfills and ‘plastic islands’ in the ocean.
FKKO plastic waste codes for recycling using IKHLYAS TECHNOLOGY technology.
- Polyethylene terephthalate
- Laminated paper
How do we prepare the raw materials?
The sorted plastic waste is loaded onto a conveyor belt which feeds the waste to a washing crusher, where it is crushed and sprinkled with water.
The crushed plastic goes into the cold washing (rinsing) Unit, where the residues of dirt and detergents are rinsed from the material.
Separation of various types of polymers, by density, and the separation of foreign inclusions from polymers.
The wringer removes the bulk of the water from the washed and crushed material. The post-drying Unit removes residual moisture.
Conclusion: Unclaimed polymer waste that does not contain chlorine is used as raw materials. Polymer waste is pre-crushed, washed, dried, and loaded into the reactor. After the recycling process, the IKHTECH plant produces fuel and lubricant fractions, ready for further use or sale.
Stage 2. Green recycling of plastic waste
Polymers destruction in reactors
The IKHTECH Unit consists of several reactors which operate in succession. The first reactor is loaded and started with the raw materials and in approximately 10-12 hours, it is completely transformed. At this point, another reactor cools down after the previous process, undergoes technological cleaning, and is then loaded with more raw materials for the next process.
Two people per shift are enough to service the Unit, however, all basic processes are automated.
The transition of plastic into a vapour-gas mixture
The plastic transforms into a vapour-gas mixture after heating with a combined oil-gas burner. The gas remains after the previous process and is sufficient to warm up the reactor. A new portion of gas is produced after reaching the operating temperature in the reactor, which is enough to maintain the process, and the excess is sent to the gasholder. Full energy autonomy of the IKHTECH Unit has been achieved.
There are no emissions of sulfur dioxide and nitrogen dioxides, as well as other hazardous and toxic substances in the combustion process, according to regular analysis of emissions into the atmosphere.
The vapour-gas mixture passes through a system of catalysts which separate the hydrocarbon-polymer chain into components. Catalysts constantly prevent steam and gas flow to be equally intense. They also select specific fractions, ignoring the thermodynamic incompatibility of polymer waste.
The remaining gas mixture is cleaned from water and gas condensate in the gas separator and sent to the gasholder or the burner through the gas pipeline. This ensures the reactor is heated by the gas produced by the process. If we take the amount of heat for one process as 100%, then 110-120% of gas is accumulated.
The process of obtaining finished products
After the completion of the plastic recycling process, the IKHTECH Unit produces useful products:
- diesel component
- mixed paraffin (slack wax)
- combustible gas, and
- carbon residue.
A container with water is required for the operation of a closed cooling system, with minimum water consumption. An electricity supply is required for the operation of the installation, with consumption up to 15 kW, for the operation of burners, pumps, compressor, and computer system. If you install a gasoline or diesel generator, it will run on fuel from the recycling process. This will allow the IKHTECH Unit to operate autonomously in areas where there are no energy sources.
System pressure does not exceed 0.06 atm — according to the technical design features of the IKHTECH Unit — and is regulated by the operator. The lack of pressure reduces the risk of emergencies. A fire extinguishing system is provided to eliminate unforeseen situations, based on the most effective water-vapour fire extinguishing in closed rooms. During the waste disposal process, sufficient steam is generated and accumulated in the fire extinguishing system.
Stage 3. The output of the gasoline fraction
EURO 4 and 5
The final product is free of hazardous metal compounds and sulfur, without additional filtration. European fuel standards Euro 4, Euro 5, and Euro 6 differ from each other in sulfur content. The lower the sulfur content, the better the product quality. There is no sulfur in the resulting products produced by the Unit since there is no sulfur in the polymer formula. The product:
- can be used as a multifunctional additive to stabilise gasoline, to increase the octane number, improve traction performance, and reduce the number of harmful emissions released into the atmosphere;
- is not subject to excise duty;
- reduces the level of taxation for the scheduled blending in the production of gasoline; and
- is ready-to-use for the production of Euro 5- and Euro 6-approved motor fuel.
Stage 4. The output of the diesel fraction
Free of hazardous metal compounds
Euro 4 and 5
The product obtained after processing can be used as diesel fuel, without additional filtration, or as a diesel additive. It is suitable for stabilising diesel fuel, increasing its cetane number and tractive performance, and for reducing harmful emissions released into the atmosphere which are usually present in petroleum diesel fuel. Using a diesel fraction as an additive during routine mixing will:
- Reduce the ignition delay time of diesel fuel;
- increase the uniformity of combustion of the diesel fuel mixture, to increase engine power and reduce fuel consumption (saving 5-7% of fuel);
- increase the completeness of diesel fuel combustion in the engine, reduce the formation of carbon deposits in the cylinder, reduce the smoke of exhaust gases, and exclude the corrosiveness of the fuel when exposed to metal; and
- reduce costs or increase profits, since the additive is a by-product of recycling polymer waste and is not subject to excise duty.
Stage 5. Synthetic gas
Up to 150 m³
Produced from 1 tonne
Can be used in any burner
And for the production of mono gases
Gas is used to operate the IKHTECH Unit. Synthesis gas is included in the production of other mono-gases and can be used in all types of gas burners. As can be seen from the attached analysis of synthesis gas, its calorific value is twice as high as natural gas and averages 11,000 kcal/m³. The calorific value of methane is 6,500-6,700 kcal/m³ for comparison.
Stage 6. Paraffin mixture (petrolatum)
Up to 30% by weight
Candles, matches, etc.
The paraffin fraction is a mixture of paraffin, which is divided into watery (melting point: 27 °C), solid (melting point: 28-70 °C), and microcrystalline (melting point: 60 – 80 °C) ceresins. Slacks (petrolatums) contain paraffin oil up to 30% of its own weight and crude paraffin, (ceresins) up to 6% oil by weight. The appearance of paraffin is a yellow/brown mass containing a significant amount of liquid hydrocarbons. The product can be used:
- for lubricant oil
- for the production of candles, matches;
- for the manufacture of ink, tracing paper, and paper
- composite wood panels;
- for the production of tarpaulin coverings;
- as fuel for heating (greenhouses, boiler houses); and
- for paraffin oil or cosmetic and medical wax.
Stage 7. Carbon residue
For the production of coal pallets
In the paint and varnish industry
Black toner for printers
The reactor must be mechanically cleaned of carbon residue after the end of the thermal destruction and cooling process. The carbonaceous residue can be used industrially as a raw material.
Competitive advantages of our technology
Some companies also declare that they have the technology for producing fuel from polymers and talk about recycling plastic waste.
Straight-run fuel without additional heating and distillation
Other companies’ technologies produce fluids which can burn but are made up of long chains of hydrocarbons. These fluids release many toxic compounds, including harmful formaldehyde, when they burn. They are very dangerous due to their volatility and high water solubility.
IKHTECH Unit’s emission protocols indicate full compliance with environmental regulations. All documents can be viewed here.
Refineries heat liquids, obtained after primary processing to high temperatures, to process them into useful fractions (gasoline and diesel). This is unprofitable because refining essentially requires a fully-fledged oil refinery.
The Ikhlyas technology and IKHTECH equipment allow you to receive finished processed products immediately or reduce the costs of adjacent production facilities.
100% Recycling of plastic waste
Some companies declare that they achieve a plastic waste recycling rate of 30% to 60% of the total amount of plastic waste accepted for recycling.
Ikhlyas is focused on recycling 100% of plastic waste, and this goal has already been achieved!
The IKHTECH Unit can work autonomously without external energy sources.