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The pyrolysis process in Plastcon

MAKEEN Energy’s Plastcon system is based on a technology known as pyrolysis – a process in which material, here plastic, is exposed to high temperatures in an oxygen-free environment. With the pyrolysis technology in Plastcon, it possible to thermally recycle all types of plastic waste from both industry and households – and importantly, to do it without any pre-treatment of the plastic. No cleaning and no sorting. 

The result of the pyrolysis process in Plastcon is a chemical and physical separation of the different molecules in the plastic. More specifically, Plastcon converts the harmful plastic waste into pyrolysis oil, gas and carbon black – and we can then use these resources again. For example, in the production of new plastic products and as a low-emission fuel for ships and trucks.

The animation and bullets here give an overview of how Plastcon – and its essential pyrolysis process – converts harmful plastic waste into useful resources:

Plastic waste

1. Plastic waste

Plastcon can process all types of plastic waste from both industry and households, without the same necessary pre­treatment as mechanical recycling requires.

Shredder

2. Shredder

The shredder cuts the plastic waste into small pieces.

Sorting system

3. Sorting

The plastic feedstock, now in small pieces, goes through sorting mechanisms that remove pollution like glass, sand, stone, metal and organic materials.

Densifier

4. Densifier

The plastic pieces are heated up to 200°C (392°F) and melted into a coherent mass. This decreases the volume with 60-80%.

Pyrolysis tank

5. Pyrolysis

The reactor vaporises the mass at 400-700°C (752-1292°F) in an oxygen-free environment.

5a. Carbon black

The first end product is now ready: carbon black. About 10% of the plastic waste has been turned into carbon black that can be used to colour new plastic materials.

Condensation

6. Condensation

The vapour from the reactor is send through condensers and liquefied into crude oil.

Gas cylinder

7a. Gas

The second end product is now ready: gas. About 15% of the plastic waste has been turned into gas that can be used to produce power or heat.

Pyrolysis oil

7b. Pyrolysis oil

The third end product is now ready: pyrolysis oil. About 75% of the plastic waste has been turned into pyrolysis oil. This can be used to produce new plastic materials – or processed to become 60% marine gas oil (MGO) and 40% naphtha. Then, marine gas oil can serve as a low-emission fuel for ships and trucks, while naphtha be used in the production of plastic items.