WO2017017692A2

WO2017017692A2 - Multi-stage cracking system and process thereof for conversion of non-degradable waste into fuels

Info

Publication number: WO2017017692A2
Application number: PCT/IN2016/000197
Authority: WO
Inventors: Suraj MUNDHE; Jan Vink; Yogesh KODE
Original assignee: Nespro Renewable Energy Solutions; Praesto Life Science Private Ltd
Current assignee: Nespro Renewable Energy Solutions; Praesto Life Science Private Ltd
Priority date: 2015-07-29
Filing date: 2016-07-28
Publication date: 2017-02-02
Anticipated expiration: 2018-01-29
Also published as: WO2017017692A3

Abstract

Disclosed is a multi-stage cracking system (1000) and process (100) thereof for conversion of non-degradable waste into energy products. The present system and method converts organic waste viz; waste polymers / plastic into various energy products in different form viz; 60% liquid, 30% gas and 10% solid. The energy products produced in the process having good calorific valve and can be used for various industrial heating applications viz; boiler, heater, diesel generators, as an alternate / substitute for furnace oil and the like.

Description

MULTI-STAGE CRACKING SYSTEM AND PROCESS THEREOF FOR CONVERSION OF NON-DEGRADABLE WASTE INTO FUELS

Field of the invention

The present process relates to a field of non-degradable waste processing, and more particularly be used to produce solid, liquid and gaseous energy products form waste plastics by pyrolysis and catalytic cracking. Background of the invention

Waste plastics, that are synthetic polymer-containing substances, pose an environmental issue because of the problems associated with disposal, a large volume of non-biodegradable material. A study performed by the Environmental Protection Agency (EPA) states that approximately billions tons of waste plastic is generated globally. However, statistics show that ~10% of waste plastic is recycled, ~25% is incinerated and the remaining ~65% is literally dumped in landfills. The estimated cost of end-to-end waste plastic management is ~$ 2800 per ton of waste plastic. Incineration is an alternative to landfill disposal of plastic waste, however this practice result in formation of unacceptable emission of gases viz; nitrous oxide, sulphur oxide, dusts, dioxins and other toxins etc. The option of secondary or mechanical recycling is the reprocessing of waste plastic into new plastic products with a lower quality level. Economic considerations for processing waste plastic often require the use of the unseparated mixed waste plastic. Plastic recycling originated with the manufacture of synthetic thermoplastics. Rejected parts, trim, and flash from operations represented valuable materials that were ground and recycled with virgin material. This process was potentially repeated a number of times provided the percentage of regrinds remained low. As long as the plastic scrap generated by the industry

l was clean and uncontaminated with other plastics, reprocessing within the industry continued to expand, provided the price of virgin plastic remained high.

Basically, Municipal Corporation, Local Governing Authorities, Food Processing and Packaging Industries have major problems as the waste cannot be dumped due to insufficient available land as well 'No Techno-Commercial Feasible Treatment Methodologies' for the treatment of produced non-degradable waste. Because of the limits on landfill capacity, future recycling or decomposition is a necessity. Direct recycling back to the manufacture is not always feasible because such waste plastic is often mixed with respect to polymer type and separation is uneconomical. Moreover, the concern authorities have to pay huge amount for the transportation and disposal of generated waste. These plastic scraps have been so far disposed of mostly by being dumped at land reclamation sites, processed for the production of flower boxes and piles, and sorted out and reclaimed as raw material. Since they occur every day in such huge volumes, such measures of disposal are hardly sufficient for their complete disposal. The open areas and the methods adopted for their disposal are rapidly reaching their limits.

US patent application 5849964 teaches a process is disclosed for processing used or waste plastic materials in order to recover chemical raw materials and liquid fuel components by depolymerisation of the used materials, which are transformed into a pumpable and into a volatile phase. The volatile phase is separated into a gaseous phase and a condensate or condensable depolymerisation product, which are refined by standard usual procedures. The pumpable phase remaining once the volatile phase is separated is subjected to liquid phase hydrogenation, gasification, low temperature carbonisation or to a combination of said processes. The condensate can be converted into a high- grade synthetic crude oil (syncrude), for example by hydrotreating on fixed-bed commercial Co-Mo or Ni-Mo catalysts, or it can be brought directly into chlorine- tolerating chemico-technical processes or typical oil refinery processes as a hydrocarbon-containing basic substance. The main drawback of this process is that the process is more complicated; number of operation involved is more and involves high pressure and high temperature in the same.

Another patent application WO2013087480A4 teaches a process and catalyst system for thermal catalytic cracking of pyrolysis derived organic molecules comprising at least a first organic catalytic material and a second organic catalytic material. The first organic catalytic material has a pyrolysis organic molecule pore absorption volume of at least two times that of the second organic catalytic material and the mass ratio of the first organic catalytic material and the second organic catalytic material is in the range of 10:0.1. The main drawback of this process is that the process is more complicated; number of operation involved is more and involves high temperature in the same. There is no consideration of pressure in the process. Total process is laboratory oriented no commercial viable process available.

Moreover, the combustion of plastic scraps entails partial generation of heat and temperatures so high as to defy control by existing techniques of combustion and, moreover, evolves noxious gas and soot in amounts so large as to cause a public nuisance by air pollution. One of the major reasons behind disposal of non-degradable waste is that current commercial methodologies available in the market are not economically viable technology for the treatment and disposal of the generated waste polymers or waste plastic. Accordingly, there exist a need to provide technically feasible, economically viable, eco-friendly, pollution free process for which overcomes existing drawbacks of the prior art. Objects of the invention

An object of the present invention is to facilitate a self-sustainable energy treatment system and method for non-degradable wastes. Yet another object of the present invention is to enable zero discharge of the treated effluents in the environment.

Another object of the present invention is to prevent adverse impact on the society, environment and surroundings flora and fauna.

Summary of invention

Accordingly, the present invention provides a multi-stage cracking system and a process for conversion of non-degradable waste into fuels. The system comprises a base, a feeder, a first reactor, a quench drum, a second reactor, a refining column, a first heat exchanger, a second heat exchanger, a first tank and a second tank. The feeder that incorporates a hopper configured on top of a first conveyer that receives shredded and segregated raw materials therein, and a second conveyor placed perpendicularly with the first conveyer to prevent chocking of material during feeding of the raw material. The first reactor is capable of transforming raw material into a hydrocarbon vapor mixture in the presence of catalyst. The first reactor has an inner shell and an outer shell. The quench drum is capable of receiving catalytically cracked hydrocarbon vapor mixture from the gas outlet of the first reactor at one end. Further, the second reactor configured with a vertical shell and a horizontal shell. The horizontal shell adaptably connects the first tank to collect the oil extracted therefrom. The refining column adaptably connects the first tank to collect the oil extracted therefrom. The first heat exchanger and the second heat adaptably receiving exhaust gas allowing treated fumes to be collected and stored in tanks connected therethrough.

In another aspect of the present invention provides the process for treating and conversion of non-degradable waste into fuels using the multi-stage cracking system. The process comprises of: feeding shredded and segregated raw material that has moisture content of less than 5% to the first reactor (200) through the feeder (150) at rate of 5 kg/hr to 45 kg/hr; then partially degrading raw material to 80 to 85 % hydrocarbons in the presence of a catalyst at cracking temperature ranging in between 250 to 450 degree Celsius at atmospheric pressure in absence of oxygen in the first reactor (200); intermediate quenching of the partial degraded raw materials using the quench drum (250) to retain the higher molecular weight hydrocarbons and send back into the first reactor (200); complete cracking of the quenched lower molecular weight hydrocarbons from the quench drum (250) in the presence of a catalyst at cracking temperature ranging in between 200 to 300 deg. Celsius in the second reactor (300) into hydrocarbon fumes and crude oil (A); rectifying of fumes of hydrocarbons along with cracked simpler hydrocarbons other than condensate in the refining column (400) into rectified fumes and crude oil (B); condensing rectified fumes in the first heat exchanger (500) into a high calorific oil (C) and collecting in the first tank (700); re-condensing non-condensed fumes from the first heat exchanger (500) in the second heat exchanger (600) into a high calorific oil (D) and collecting in the first tank (700); collecting non-condensed fumes from the second heat exchanger (600) and compressing at pressure of 6 bar (g) for storing in the second tank (800), and converting uncracked polymers into a sludge._^

Brief description of the drawings

Figure 1 shows a schematic view of a multi-stage cracking system.

Figure 2 shows a feeder, in accordance with one aspect of the present invention.

Figure 3 shows a first reactor, in accordance with one aspect of the present invention.

Figure 4 shows a quench drum, in accordance with one aspect of the present invention.

Figure 5 shows a second reactor, in accordance with one aspect of the present invention.

Figure 6 shows a refining column, in accordance with one aspect of the present invention.

Figure 7 shows a first heat exchanger / oil condenser, in accordance with one aspect of the present invention.

Figure 8 shows a second heat exchanger / gas condenser, in accordance with one aspect of the present invention.

Figure 9 shows a first tank / an oil storage tank, in accordance with one aspect of the present invention.

Figure 10 shows a second tank / a gas storage tank, in accordance with one aspect of the present invention. Detailed description of the invention

The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.

The present invention provides a multi-stage cracking system and process thereof for conversion of non-degradable waste into energy products in all solid, liquid and gaseous form. The non-degradable waste / raw materials for the present particularly includes waste polymers i.e. organic waste plastic in form of polyethylene, polypropylene, polyester, polyvinyl chloride, polystyrene, polyethylene terephthalate, polyvinylidene chloride, low density polyethylene, high density polyethylene, acrylonitrile butadiene styrene, nylon and the like.

In one aspect, the present invention provides a multi-stage cracking system (1000) (hereafter referred to as 'the system (1000)'). Referring to figure 1, a schematic vie of the system (1000) of the present embodiment is shown. The system (1000) includes a base (Not Shown), a feeder (150), a first reactor / catalytic cracker (200), a quench drum (250), a second reactor / reboiler/ catalytic re-cracker (300), a refining column (400), a first heat exchanger / oil condenser (500), a second heat exchanger / gas condenser (600), a first tank / an oil storage tank (700), a second tank / a gas storage tank (800) and a sludge screw and collection unit (900).

The base in the preferred embodiment is a solid ground or a vehicle floor in accordance to the requirement from a user to make the system (1000) erected in a plant or to facilitate a portable unit. The base provides platform securely mounting all the components using a plurality of fixing means. In the present embodiment, the fixing mean could be screws, nuts and bolts and the like.

Referring to figure 2, the feeder (150) of the present embodiment is shown. The feeder (150) includes a hopper (120) configured on top of a first conveyer (130) and a second conveyor (140). The feeder (150) is having angle of 5-15 degree with respect to the base most preferably at 10 degree, in order to feed the material. The hopper (120) is adapted to receive shredded and segregated raw materials from various sources. The first conveyer (130) is mounted with a geared motor (135) at one end which facilitates the rotary motion to feed the raw material in the system. The first conveyer (130) has another end connected to one end of a second conveyor (140) therefrom. The second conveyor (140) is placed perpendicularly with the first conveyer (130) to prevent chocking of material during feeding of the raw material. The second conveyor (140) allows the raw material pass therethrough. The second conveyor (140) at a second end is configured to be fixedly secured to the first reactor (200) by a fixing mean (Not Numbered). The second conveyor (140) is provided with a cooling jacket (Not Numbered). Cooling water is circulated through the jacket in order to keep the temperature of the second conveyor (140) low as it is connected directly to first reactor (200) which operates at higher temperature.

Referring to figure 3, the first reactor (200) of the present embodiment is shown. The first reactor (200) in the present embodiment is a catalytic cracker. The first reactor (200) is securely mounted on the base using the fixing means. The first reactor (200) is cylindrically shaped container configured to have atleast two chambers that is an inner shell (160) and an outer shell (170). The inner shell (160) of the first reactor (200) is incorporated with an input (Not Numbered) to receive shredded and segregated raw materials from the second conveyor (140). The inner shell (160) includes a rotating scrapper (Not Numbered) connected with a geared motor (Not Numbered) to mix or stir the raw material, a gas outlet (154) and a sludge / carbon outlet (158) further connecting the sludge screw and collection unit (900). The outer shell (170) is configured to enclose of the inner shell (160) therein. The outer shell (170) includes a plurality of stiffening rings (175) a burner (Not shown) and a gas outlet (Not Shown). The raw material is fed to inner shell (160) of first reactor (200) along with a catalyst and the outer shell (170) is then heated by firing of the burner. The raw material is heated and transform into a hydrocarbon vapor mixture in the presence of catalyst. The gas outlet (154) of the inner shell (160) is adaptably connected with the quench drum (250).

Referring to figure 4, the quench drum (250) of the present embodiment is shown. The quench drum (250) has a long cylindrical body (210) having a cooling jacket (220) thereon. The quench drum (250) having one end receiving catalytically cracked hydrocarbon vapor mixture from the gas outlet (154) of the first reactor (200). Another end of the quench drum (250) is adaptably connected to the second reactor (300) to pass the quenched vapor therefrom.

Referring to figure 5_; the second reactor (300) of the present embodiment is shown. Further, the second reactor (300) is an inverted T-shaped structure being firmly secured on the base using the fixing means. The second reactor (300) is configured with a vertical shell (270) and a horizontal shell (290). The vertical shell (270) includes a cooling tube coil (262), an inlet nozzle (264), a baffle plate (Not Shown) and an outlet nozzle (268). The inlet nozzle (264) is adaptably configured to receive the quenched vapor from the quench drum (250) which is further passed into the horizontal shell (290) of the second reactor (300). The horizontal shell (290) is cylindrical body having a heat exchanger (Not Shown) therein with a storage space (Not Shown). The horizontal shell (290) has an inlet (282) at one end for exhaust gas received from the first reactor (200) and a gas outlet (284) for the gas exhaust at another end. The second reactor (300) reheats the quenched material by obtaining heat from the exhaust gas of the first reactor (200). The generated hydrocarbon vapor is thereby allowed to pass through the gas outlet (284). The second reactor (300) includes a bottom outlet nozzle (288) adaptably connected with the first tank (700) to collect the extracted oil. The second reactor (300) is adaptably connected with the refining column (400) through the gas outlet (284) to pass completely cracked partially degraded raw material in the form of fumes / gas / vapours therefrom. The refining column (400) as shown in the figure 6 is tower shaped column having a water jacket (Not Shown) facilitating continues running water for cooling. The refining column (400) has an inlet (340) at one end to adaptably receive exhaust gas received from the gas outlet (284) and a gas outlet (360) at another end. The refining column (400) includes a bottom outlet nozzle (380). The refining column (400) facilitates rectification of the fumes and extract some traces of oil which is further collected from the bottom outlet nozzle (380) of the refining column (400) and stored in the first tank (700) connected therethrough.

After the rectification process in the refining column (400) remaining hydrocarbon vapours passes to the first heat exchanger (500) as shown in the figure 7. The first heat exchanger (500) has an inlet (440) at one end to adaptably receive exhaust gas received from the gas outlet (360) and a gas outlet (460) at another end. The first heat exchanger (500) includes a bottom outlet nozzle (480). In the first heat exchanger (500) mostly all hydrocarbon is condensed and oil is collected from the bottom outlet nozzle (480) and stored in the first tank (700) connected therethrough. The non-condensed fumes from the first heat exchanger (500) are allowed to pass through the second heat exchanger (600) for treatment of the fumes. The second heat exchanger (600) has an inlet (540) at one end to adaptably receive exhaust gas received from the gas outlet (460). The second heat exchanger (600) includes a bottom outlet nozzle (580).The treated fumes from the second heat exchanger (600) in form of gas is collected and stored in the second tank (800) connected therethrough. Specifically, in another aspect of the present invention is a multi-stage cracking process (100) (hereafter referred to as 'the process (100)') using the multi-stage cracking system (1000). The process (100) facilitates treatment and conversion of non-degradable waste viz; waste polymers or waste plastic into energy products in various form viz; solid, liquid and gaseous form. The process (100) begins with a step (10), where the shredded and segregated raw material like waste polymers / plastic with moisture content and inert material less than 5% is fed to the first reactor (200) via the feeder (150) at constant and desired feed rate. In the present embodiment, the non-degradable waste is shredded in size of 10-20 mm. The moisture content and inert material concentration of the shredded and segregated raw material is preferably less than 2-3%. The rate of feed in the present embodiment is operable between 5 kg/hr to 45 kg/hr and preferably 15 kg/hr to 30 kg/hr however it understood that feed rate may varies in accordance with the plant requirement.

Further at step (20), the waste polymers are partially degraded from complex form to simpler form of various hydrocarbons due to the presence of catalyst at atmospheric pressure in absence of oxygen. Further, the catalytically cracked raw material is mixed with predetermined quantity of catalyst is then subjected for further processing. The cracking temperature for this step is ranging in between 250 to 450 degree Celsius is achieved using an external power source like oil / gas burner (Not Numbered). The most preferred cracking temperature for this step is ranging in between 300 to 350 degree Celsius. The first reactor (200) once subjected with raw material temperature starts to rise and initiates the reaction inside the first reactor (200) which results into breakdown of hydrocarbons into partial degraded/polymerized raw materials. The process in this step brings partial breakdown of hydrocarbons upto ~ 80 to 85 % by converting complex molecular hydrocarbons into various simpler hydrocarbons in the presence of catalyst. The catalyst of the present embodiment is among various catalysts used such as bentonite, alumina, silica, alumina + silica, zeolite, V205 etc. The present step can also be operated using combination of Alumina + Silica such as (50% Alumina + 50% Silica), (40% Alumina + 60% Silica), (30% Alumina + 70% Silica), (20% Alumina + 80% Silica) and (10% Alumina + 90% Silica) etc. The present step can also be operated using different ratio of with respect to feed from 5 % to 30 %. The present invention delivers best results at 10% feed ratio by using (10% Alumina + 90% Silica).

In next step (30), the partial degraded/polymerized raw materials are allowed to pass to and are subjected to intermediate quenching using the quench drum (250). The process in this step allows the quench drum (250) to retain the higher molecular weight hydrocarbons and send them back into the first reactor (200). Further the high molecular weight hydrocarbons retained back in the first reactor (200) are again re-cracked / processed at high temperature in presence of catalyst and converted into lower molecular weight hydrocarbons which are further subjected for processing. The partial water cooling provided to quench drum (250) effectively results in separation of higher and lower molecular hydrocarbons due to the difference in their boiling point of the simpler polymerized hydrocarbons.

Further in step (40), the quenched lower molecular weight polymerized hydrocarbons obtained from the quench drum (250) are further subjected for the final cracking in the second reactor (300) at temperature between 200 to 300 deg. Celsius. The present step (40) facilitates 100% cracking of the processed material in presence of catalyst to be converted into simpler and extractable forms of hydrocarbons in the form of fumes / gas / vapours. The second reactor (300) plays a vital role in improvement of better quality and quantity of extractable hydrocarbons. The second reactor (300) being provided with partial water cooling unit allows some vapor traces to be extracted, condensed, and converted into oil. The traces of extracted oil are collected from the bottom of the second reactor (300) and stored in the first tank (700). The extracted oil in this step is crude oil (A) having various applications such as burner fuel, furnace fuel, raw material for oil refinery various industrial and domestic heating applications, raw material for extraction of various industrial chemicals, industrial and domestic heating applications production of grease and the like.

Further in step (50), the fumes of hydrocarbons along with cracked simpler hydrocarbons other than condensate are further allowed to pass through refining column (400) that facilitates rectification of the fumes using cooling water continuously circulated around the rectified column (400). Also, traces of extracted oil are collected from the bottom of the refining column (400) and stored in the first tank (700). The extracted oil in this step is better in terms of quality and quantity as compared to earlier crude oil (A). The oil collected at this stage is referred as crude oil (B) having various applications such as burner fuel, furnace fuel, raw material for oil refinery, raw material for extraction of various chemicals, industrial and domestic heating applications and the like. In next step (60), the rectified fumes other than condensate from the refining column (400) are allowed to pass through first heat exchanger (500). The first heat exchanger (500) includes a cooling tower (Not Numbered) that facilitates condensation of the rectified fumes into crude oil or fuel oil or high calorific oil (C) by passage of cold water there around. The cooling water plays a vital role in condensation of extracted or cracked fumes converting them in better quality of oil. The crude oil or fuel oil or high calorific oil (C) is also collected and stored in the first tank (700). The extracted oil in this step is best in terms of quality and quantity as compared to earlier crude oil (A) and (B). The crude oil (C) collected at this stage has various applications such as burner fuel, furnace fuel, raw material for oil refinery, various industrial and domestic heating applications, raw material for extraction of various industrial chemicals, production of grease and the like. Further in next step (70), the non-condensed fumes from the first heat exchanger (500) are allowed to pass through the second heat exchanger (600). The second heat exchanger (600) is a gas cooler which includes a cooling tower that facilitates re-condensation of the treated fumes into as crude oil or fuel oil or high calorific oil (D) and gases by passing cold water. The crude oil or fuel oil or high calorific oil (D) is collected and stored in the first tank (700). The vapours which are not condensed at this stage i.e. other than oil traces are extracted and collected from top of second heat exchanger (600) in the form of gas. The gas is compressed at desired pressure of 6 bar (kg/cm²), and stored in the second tank (800).

In next step (80), the crude oils (A), (B), (C) and (D) extracted, condensed and collected at from various steps (40), (50), (60) and (70) stored in the first tank (700) has found to be of similar properties to LDO (Low Density Oil), Furnace Oil and hence can be safely used an alternative fuel for various industrial applications thus conserving depleting natural resources.

In final step (90), the un-cracked polymers i.e. which are neither converted into gas nor oil are converted into solid fuel viz; sludge or semi-solid carbon. The physical appearance of this semi-solid carbon may vary from powder, lumps, semi-solid, slurry and the like depending upon the type of raw material and process operational conditions. However any of the form of carbon or sludge can be effectively used as solid fuel for boilers or any other solid heating applications for various industrial applications from case to case. Specifically, the present method and system converts organic waste viz; waste polymers / plastic into various energy products in different form viz; 60% liquid, 30% gas and 10% solid.

The gas stored in the second tank (800) is used as process fuel for various heating application especially in the preferred embodiment as a fuel for the first reactor (200) at step (10) making process economically feasible in terms of energy consumption as well thereby minimizing air pollution too. The gas produced in the process is compressed at 6 bar (kg/cm2), stored in gas storage , tank as further used as a process fuel for the catalytic cracker at 200-300 mbar which make the process almost self-sufficient (80 - 90%) in terms of energy requirements. If the produced gas is insufficient as process fuel then in that case produced process crude oil is used partially viz; around 10% of the produced quantity as process fuel. The produced fuel in various forms viz. gas and liquid facilitates self-sustainable energy requirement of the system (1000).

Table 1 details data collected for conversion of 1000 kg per day of Waste Plastic / Polymer in various products for the present invention:

In the test run carried out for the 1000 kg per day of Waste Plastic / Polymer 30% produced flammable gas was used in combination with 10% of produced crude oil as process fuel for plant operations. The process operations were hence found self-sufficient in terms of energy consumption. The balance of energy products viz; crude oil and sludge were tested for various industrial heating applications viz; boiler, heater, diesel generators, as an alternate / substitute for furnace oil and the like.

Table no. 2: shows approximate crude oil composition obtained:

Table no. 3: shows approximate flammable gas composition obtained:

Table no. 4: shows approximate sludge / carbon composition obtained:

Advantages of the invention

The system (1000) and method (100) facilitates a self-sustainable energy treatment method for non-degradable wastes.

The system (1000) and method (100) provides 100% decomposition of waste plastic.

The system (1000) facilitates continuous process along with compact design thereby resulting in effective utilization of required space and machinery for process plant.

The system (1000) has customized best effective design based on earlier field experience for ease of maintenance and operation process.

The system (1000) and method (100) provides better product efficiency in terms of quality and quantity of produced end energy products.

The system (1000) and method (100) eliminates unnecessary process equipment's for better process efficiency / performance which results in reduction of basic project capital investment. The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

We Claim

1. A multi-stage cracking system (1000) for conversion of non-degradable waste into fuels, characterized in that the system (1000) comprising: a base,

a feeder (150) capable of being placed on the base at angel 5-15 degrees, the feeder (150) incorporates

a hopper (120) configured on top of a first conveyer (130) receiving shredded and segregated raw materials therein, and

a second conveyor (140) being placed perpendicularly with the first conveyer (130) to prevent chocking of material during feeding of the raw material;

a first reactor (200) capable of transforming raw material into a hydrocarbon vapor mixture in the presence of catalyst, the first reactor (200) having

an inner shell (160) configured with an input connecting the second conveyor (140), a gas outlet (154) and a sludge / carbon outlet (158) connecting a sludge screw (900) therethrough, and

an outer shell (170) enclosing the inner shell (160) therein, the outer shell (170) includes a plurality of stiffening rings (175) a burner and a gas outlet;

a quench drum (250) being capable of receiving catalytically cracked hydrocarbon vapor mixture from the gas outlet (154) of the first reactor (200) at one end,

a second reactor (300) reheating the quenched material, the second reactor (300) configured with

a vertical shell (270) including an inlet nozzle (264) adaptably configured to receive the quenched vapor from the quench drum (250), a cooling tube coil (262), a baffle plate and an outlet nozzle (268); and a horizontal shell (290) having a heat exchanger therein receiving exhaust gas from the first reactor (200) and a gas outlet (284) for the gas exhaust at another end, wherein the horizontal shell (290) includes a bottom outlet nozzle (288) adaptably connected with a first tank (700) to collect the extracted oil therefrom;

a refining column (400) having an inlet (340) at one end adaptably receiving exhaust gas from the gas outlet (284), a gas outlet (360) at another end and a bottom outlet nozzle (380) adaptably connected with the first tank (700) to collect the extracted oil therefrom;

a first heat exchanger (500) having an inlet (440) at one end adaptably receiving exhaust gas received from the gas outlet (360), a gas outlet (460) at another end and a bottom outlet nozzle (480) adaptably connected with the first tank (700) to collect the condensed oil therein; and a second heat exchanger (600) having an inlet (540) at one end adaptably receiving exhaust gas received from the gas outlet (460) and a bottom outlet nozzle (580) allowing treated fumes to be collected and stored in a second tank (800) connected therethrough.

2. The system (1000) as claimed in claim 1, wherein the feeder (150) is placed on the base at angel 10 degrees.

3. The system (1000) as claimed in claim 1, wherein the second reactor (300) is an inverted T-shaped structure.

4. The system (1000) as claimed in claim 1, wherein the base a solid ground or a vehicle floor allowing the system (1000) to be a standalone plant or portable unit.

5. A process (100) for treating and conversion of non-degradable waste into fuels using the multi-stage cracking system (1000) as claimed in claim 1, the process (100) comprising of:

feeding shredded and segregated raw material having moisture content of less than 5% to the first reactor (200) through the feeder (150) at rate of 5 kg/hr to 45 kg/hr;

partially degrading raw material to 80 to 85 % hydrocarbons in the presence of a catalyst at cracking temperature ranging in between 250 to 450 degree Celsius at atmospheric pressure in absence of oxygen in the first reactor (200);

intermediate quenching of the partial degraded raw materials using the quench drum (250) for retaining the higher molecular weight hydrocarbons and sending back into the first reactor (200);

complete cracking of the quenched lower molecular weight hydrocarbons from the quench drum (250) in the presence of a catalyst at cracking temperature ranging in between 200 to 300 deg. Celsius in the second reactor (300) into hydrocarbon fumes and crude oil (A);

rectifying of fumes of hydrocarbons along with cracked simpler hydrocarbons other than condensate in the refining column (400) into rectified fumes and crude oil (B);

condensing rectified fumes in the first heat exchanger (500) into a high calorific oil (C) and collecting in the first tank (700);

re-condensing non-condensed fumes from the first heat exchanger (500) in the second heat exchanger (600) into a high calorific oil (D) and collecting in the first tank (700);

collecting non-condensed fumes from the second heat exchanger (600) and compressing at pressure of 6 bar (g) for storing in the second tank (800); and

converting uncracked polymers into a sludge.

The process (100) as claimed in claim 5, wherein the moisture content of the shredded and segregated raw material is less than 2-3%.

The process (100) as claimed in claim 5, wherein the raw material is shredded in size of 10-20 mm.

8. The process (100) as claimed in claim 5, wherein the rate of feed is in between 15 kg/hr to 30 kg/hr.

9. The process (100) as claimed in claim 5, wherein the cracking temperature for is ranging in between 300 to 350 degree Celsius

10. The process (100) as claimed in claim 5, wherein the catalyst is bentonite, alumina, silica, alumina + silica, zeolite, V₂0₅ and the like.

11. The process (100) as claimed in claim 5, wherein the catalyst is combination of Alumina + Silica in ratio of (50% Alumina + 50% Silica), (40% Alumina + 60% Silica), (30% Alumina + 70% Silica), (20% Alumina + 80% Silica) and (10% Alumina + 90% Silica) and the like with feed ratio of

5 % to 30 %.

12. The process (100) as claimed in claim 5, wherein the catalyst is combination 10% Alumina + 90% Silica to feed ratio of 10%.