An estimated 6.3 billion tons of plastic waste had been generated as of 2015, of which only 9% was recycled. If current plastic production and waste management trends continue, 12 billion tons of plastic will be in landfills, the oceans and the natural environment by 2050.
Global plastic production was reported to be around 299 million metric tons in 2013, which significantly increased to 335 million metric tons in 2016.
It has been calculated that 275 million metric tons of plastic waste was generated in 192 coastal countries in 2010, with up to 12.7 million tons entering the ocean in a single year. Following this trend, the total weight of plastic in the oceans will exceed the weight of fish by 2050!
The United Nations reported that the approximate environmental damage caused by plastic to marine ecosystems comes to approximately 15 billion US Dollars and growing exponentially.
FLOATING PLASTIC ISLAND IN THE OCEAN
THE HERCULES SERIES 1 is a complete Waste Plastic to Fuel Production System designed and manufactured by PETRONIX INDUSTRIES. It features clean, efficient operation, and production of high quality, low sulfur, synthetic fuel from a wide range of waste plastics.
After producing numerous fully functioning systems over a period of several years, Petronix Industries team of scientists and engineers broke new ground with creation of the Hercules Series 1. This model features cutting edge, industry-leading, unrivaled eco-friendly application of PETRONIX INDUSTRIES proprietary PYROCATALYSIS technology.
Key Features: Production capacity of converting 25,000 kilograms of plastic into an average of 18,000 liters of pyrolysis crude oil equivalent (similar to Brent Light Sweet Crude). A fully continuous, fully enclosed reactor allowing no noxious fumes to be released into the atmosphere. Non-stop “Batch” and “Continuous” operation, 24 hours a day, 330 days per year. Ultra-low sulfur fuel produced can be used without refining for low speed diesel engines. Unprecedented refined fuel yield of 50-60% EN590 standard diesel, over 20% naphtha, with additional products of kerosene and light fuel oil. Space-efficient design with small footprint considering the scale of production. Modular system that is easily scalable and maintenance-friendly.
Production Specifications: Projected production from 25,000 kilos of plastic per day is: Pyrolysis Crude Oil – 18,000 liters - Solid (Char) – 3.5 tons & Gas – 3.5 tons
Feedstock: The Hercules Series 1 accepts most types of waste plastic. Preferred feedstock is Polyethylene (PE), Polypropylene (PP) and Polystyrene (PS) with a projected fuel yield of up to 70%.
Heating the Reactor: Any fuel can be used to heat the reactor depending on cost and local availability. The Hercules Series 1 features a closed cycle system of channeling gas and solid byproducts of the process, back to provide up to 50% of heating fuel needed.
Electrical Power Consumption: 55kW per hour, or less than one kWh of electricity per liter of fuel produced.
Manpower: 24-hour operation takes a workforce of 10-12 persons – 3-4 staffs per eight-hour shift, 2 persons/shift for batch production.
Service Life: The Hercules Series 1 has a longer lifespan than most systems available on the market. Minimum service life is 5 years.
Life Expectancy: Approximately 5-10 years.
Emissions: Exhaust from the furnace heating the Hercules Series 1 is sent through a scrubber unit before being released as excess heat and a small amount of CO2. This means that the system produces virtually no pollutants whatsoever – whether into the air, ground or waterways.
Petronix Industries is totally committed to working with Continents, Countries, Cities and local municipalities to rid their environment of plastic waste which has been one of the largest man made disasters to date. Petronix Industries is the ONLY company in the marketplace that uses Pyrolysis technology along with the use of our proprietary Pyrocatalysis technology to process waste plastic into high grade petroleum leaving zero carbon footprint in the process. This advanced Pyrocatalysis Technology ensures the stability and longevity of the processed petroleum products.
FEEDSTOCK: The system accepts any type of plastic except PVC. PET plastic which is not recommended. Tire, rubber, oil sludge, and petroleum-based medical waste can all be used.
HEATING THE REACTOR: Recommended fuel to heat the reactor is firewood. This is the most economical option in PETRONIX INDUSTRIES prototype system. Other possible fuels are gas, other fossil fuels, coal, etc. This also includes petroleum produced from the system. The Hercules Series 1 model requires 1.75MW of thermal energy per hour. Heating of the reactor is structured using 50% gas and char residue from the process, and 50% firewood.
ELECTRICAL POWER CONSUMPTION: 55kW per hour, or less than one kWh of electricity per liter of fuel produced.
MANPOWER NEEDED: 24-hour operation takes a workforce of 9-12 persons – 3-4 per eight-hour shift for batch plants, 2 persons for continuous production plants.
PRODUCTION PLANT SIZE SPECS
1. Mobile Plant - 10 Tonnes | Day
2. Non-Mobile Plant - 25 Tonnes | Day
3. Non Mobile Plant - 50 Tonnes | Day
All types of used and discarded tires.
Petronix Pyrocatalysis Processing Plant.
All plastic bags & styrofoam containers.
All types of plastic bottles & wrappers.
Petroleum by-products after processing.
All types of plastic medical products.
- A 20 foot container being shipped from Shanghai to Hamburg emits approximately 37 kilos of sulfur. This is equivalent to 3,950 cars emissions during the same period of time.
- An entire container ship at 8,000 TEU (Twenty-foot Equivalent Unit) sailing from Shanghai to Hamburg emits as much sulfur as 31.6 million cars emits during its 28 days at sea!
- This means that only 24 of 8000 TEU containerships emit as much sulfur as the ENTIRE WORLD WIDE CAR FLEET!
Ocean-going vessels and large ships traditionally used “bunker fuel” with sulfur levels as high as 5%, or 50,000 ppm, sulfur. Bunker fuel burned on these ships was a large source of harmful air pollution in the U.S.
An international treaty designated two Emission Control Areas (ECA) covering U.S. waters. The North America ECA extends 200 miles from the shores of North America, and the U.S. Caribbean Sea ECA covers waters around Puerto Rico and the U.S. Virgin Islands. The sulfur content of the fuel used in marine vessels operating in these ECAs may not exceed 0.10 weight percent (1000 ppm).
Note that a global sulfur cap of 3.50 weight percent applies outside of ECA boundaries. This limit decreases to 0.50 weight percent in 2020.
Before EPA began regulating sulfur in diesel, diesel fuel contained as much as 5,000 parts per million (ppm) of sulfur. EPA began regulating diesel fuel sulfur levels in 1993. Beginning in 2006, EPA began to phase-in more stringent regulations to lower the amount of sulfur in diesel fuel to 15 ppm. This fuel is known as ultra-low sulfur diesel (ULSD). EPA’s diesel standards target emissions from two different sources:
Collectively, diesel standards reduce harmful emissions from both onroad and nonroad diesel sources by more than 90%.
EPA participates on the U.S. delegation to the International Maritime Organization (IMO), which is part of the United Nations. The Marine Environment Protection Committee (MEPC) is a group of member states within IMO that works on maritime safety and security and the prevention of marine pollution. The resulting global standards are embodied in the International Convention on the Prevention of Pollution from Ships, a treaty called "MARPOL." In particular, MARPOL Annex VI defines engine and vessel requirements related to air pollution.The first round of standards under MARPOL Annex VI, adopted in 1997 and entered into force in 2005, involved maximum allowable sulfur concentrations in marine fuels, and maximum oxides of nitrogen (NOx) emission rates in engine exhaust. MARPOL Annex VI was amended in 2008, most importantly to set more stringent fuel sulfur limits and more stringent NOx emission standards, especially for vessel operation in designated Emission Control Areas (ECAs).Together with Canada and France, the U.S. Government successfully petitioned the International Maritime Organization to designate the North American Emission Control Area for both fuel-sulfur standards and NOx emission standards. This area includes most coastal waters up to 200 nautical miles from the coasts of the continental United States and large portions of coastal waters around Alaska and Hawaii, in addition to significant portions of the Canadian coasts and the French Islands of Saint Pierre and Miquelon.The U.S. Government later successfully petitioned the International Maritime Organization to also designate the U.S. Caribbean Sea Emission Control Area for both fuel-sulfur limits and NOx emission standards. This area includes waters surrounding Puerto Rico and the U.S. Virgin Islands.Vessels operating in Emission Control Areas must meet the following requirements:
The international standards apply to both U.S. vessels and to foreign vessels. Engines installed on U.S. vessels are also subject to fuel standards and engine emission standards that EPA has adopted under the Clean Air Act.