PLETHORA PYROLYSIS

Submitted by: Niketa Khattar PGDM IB (230) Nikhil PGDM IB (231) Ankit Khandelwal PGDM IB (268)

Service Description:
For many years, various methods are tried and tested for processing of waste plastic. The plastic materials are recycled and low value products are prepared. Plastic materials which cannot be recycled are usually dumped into undesirable landfill.

Worldwide almost 20% of the waste stream is plastic, most of which still ends up in landfill or at worst it is incinerated. This is a terrible waste of a valuable resource containing a high level of latent energy.

In recent year this practice has become less and less desirable due to opposition from Government and environmentally conscious community groups. The value of plastics going to landfill is showing a marginal reduction despite extensive community awareness and education programs.

Research Centre for Fuel Generation (RCFG) has conducted successful 300 successful pilot trials and commercial trials for conversion of waste plastic materials into high grade industrial fuel. The system uses liquefaction, pyrolysis and the catalytic breakdown of plastic materials and conversion into industrial fuel and gases. The system can handle the majority of plastic materials that are currently being sent to landfill or which have a low recycle value.

Catalytic conversion of waste plastic into high value product is a superior method of reusing this valuable resource.

The distillate fuel is an excellent fuel and can be used for 1) Diesel electrical generators 2) Diesel burners / stoves 3) Boilers 4) Hot air generators

5) Hot water generators 6) Diesel pumps

The distillate can be further fractionated into fuels as under and can be used in automobiles. 1) Petrol 2) Kerosene 3) Diesel

Industry Analysis:
So far this stream is untapped. There are only 20-22 companies working with this technology. This field have a lot potential for expansion. Very few are known to this technology giving opportunity to enter in this field. We have raw material abundantly available along with buyers of final product. Demand of such a plant is increasing day by day.

Financial Plan :
Given below table shows all the expenses, investment and profit made in an year: Sr. No. 1 2 3 4 B. 1 A B 2 3 4 a) b) c) 5

PARTICULARS Machinery + Pipe fittings + Installation etc. (As per list enclosed in K above) Land (10000 sq.ft.) Factory shed (100 sq. Meters @ Rs. 3000/- per sq meter) Lab. Equipments, Furniture & Fixtures One months production expenses Raw Materials Waste plastic 25,000 kg. Water and chemicals Electrical expenses Packing cost Salaries Manager 1x Rs.10,000 p.m. Production Supervisor 3 x Rs. 5,000 pm Helpers 9 x Rs.4,000/- p.m. Administrative Cost: Office expenses, transportation telephone etc.

Rs.

Rs. 25,00,000 NIL 3,00,000 25,000

Rs.

1,55,000 1,25,000 30,000 NIL NIL 61,000 10,000 15,000 36,000 15,000

NIL NIL 61,000

Total one months recurring expenses Two months working capital Fixed assets Total Capital Investment Total Project Cost (In lacs) (round up) 6 Cost of production per annum a) Fuel production cost (Rs. 16.59 X 210000 Liters) b) Activated carbon production cost (Rs. 01.60 X 15000 kg.) Total production cost Yearly receipts: a) Industrial fuel sale (210000 liters X Rs. 30) b) Activated carbon sale (15000 kg. X Rs. 30) Total receipts Gross Profit per annum

2,31,000 4,62,000 28,25,000 32,87,000 33

34,83,900 24,000 35,07,900

63,00,000 4,50,000 67,50,000 32,42,100

Marketing Strategy:
We will be giving samples with test report from reputed and approved laboratory.

As the fuel is cheaper and of better quality, the marketing efforts are almost nil as the buyer is benefited. The buyers are readily available all effort to be made is locating the buyers in periphery of the plant or the buyers who will be dealing in bulk with us.

Operational Strategy
The raw materials include following: 1) Polyethylene: Buckets, drums, Chapels, sandal, bottles, plastic 2) Polypropylene: Pipe fitting, filter cloths etc. 3) Polyamide: Nylon ropes 4) Polyvinyl Chloride (PVC): PVC pipes and fittings 5) Polystyrene: Cloths and fiber 6) Rubber: Tires, automobile parts parts, carry bags etc.

7) Electronic Goods: Telephone sets, computers, keyboards, monitors laptops, electronic devices etc. Whole process can be explained with following diagrams:

Manpower Planning:
Plastic Pyrolysis Plant require low manpower as it spreads over 10,000 sq. feet including plant, storage area and tanks for fuel storage. Plant requires 1 Manager, 3 Supervisors and 9 helpers for operating plant. Considering raw material supply and supply of fuel to potential buyers all in all 50 personnel will be required.