WO2025062423A1

WO2025062423A1 - Upcycling of plastics into fuels and value-added chemicals

Info

Publication number: WO2025062423A1
Application number: PCT/IN2024/051779
Authority: WO
Inventors: B.V. Satish Kumar; B. Sheela
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-09-19
Filing date: 2024-09-18
Publication date: 2025-03-27
Anticipated expiration: 2026-03-19

Abstract

The present invention relates to a system and method for the conversion of plastics to hydrocarbons in a single-step process. The plastics may include industrial plastics or municipal waste plastics. The system comprises a series of kilns, hot condensers, cool condensers, gas distributors and receptacles. Waste plastics freed of moisture and oxygen, are slowly heated upto 400°C. Initially, the fraction containing hydrocarbons below C₂₀ is separated. The hydrocarbon fraction of C₁₄ to C₂₀ is then cracked to yield C₇ - C₁₀ and C₁₀ - C₁₄ fractions. The hydrocarbon fraction lighter than C₁₄ is further cracked and C₇ to C₁₀ hydrocarbon fraction is collected. C₁₀ hydrocarbon stream is then separated into C₉ and C₈ hydrocarbons. Lighter hydrocarbons of C₅ to C₇ are further collected. Said system does not use any catalyst and no induced pressure is used beyond ambient pressure.

Description

FIELD OF THE INVENTION

The present invention relates to a process for the upcycling of plastics including industrial plastics and municipal plastic wastes, into fuels and value-added chemicals.

BACKGROUND OF THE INVENTION

The global plastic waste volumes are expected to grow to 460 million tons per year by 2030, taking what is already a serious environmental problem to a whole new level. In most emerging markets, countries lack infrastructure for sorting trash into different waste streams. As these countries build up their waste-management capabilities, the first step will be to separate the plastic waste from other wastes. Once this is achieved, pyrolysis of mixed plastic waste is the most efficient way to process it, until capabilities are in place to separate different plastics.

Considering the fact that plastics reuse and recycling could drive the majority of value creation in petrochemicals during the coming decade, it is imperative that technologies be developed to meet the industry’s needs. Various fractions of hydrocarbons can be produced from plastic wastes when subjected to pyrolysis. In pyrolysis, thermal polymerization, depolymerization or cracking of plastics takes place at a temperature ranging from 300 to 900°C. in the absence of oxygen thus producing liquid and gaseous fuel and carbonized char.

Plastics formed by the polymerization of multiple molecules are decomposed into small molecular hydrocarbon compounds through pyrolysis carried out at high temperatures. The plastic wastes are contained in a reaction container and thermal energy is provided to heat the reaction container, so that the plastic wastes in the reaction container are melted and then gasified and pyrolyzed into a variety of small hydrocarbon compounds. During such pyrolysis process, the temperature and pressure of the reaction container are required to be accurately controlled, wherein the temperature of the reaction container, too high or too low, will adversely affect the reacting plastic and the efficiency of the whole process.

US 11518940 relates to a plastic recycling system and method that provides a plastic recycling system and method adapted for thermal decomposition process, such as pyrolysis, for plastic material and it can be precisely controlled throughout the process.

US10717934B2 relates to a mixed plastic waste recycling apparatus for conversion of mixed plastic waste into a liquid hydrocarbon product, wherein the recycling apparatus comprises a fluidized bed pyrolysis reactor configured to contain a fluidized bed of particulate material, a condenser to form a liquid fraction and a gas fraction, a monitor for measuring heat of combustion, a controller for maintaining the temperature of fluidized bed pyrolysis reactor so as to maintain the liquid fraction within a certain range. The mixed plastic waste recycling apparatus is configured to treat from 5,000 to 20,000 tonnes per year of mixed plastic waste.

US 10975313 B2 relates to the production of aromatic hydrocarbons from mixed plastics via processes which include pyrolysis, hydroprocessing, reforming, and disproportionation and alkylation, wherein benzene and xylenes are the preferred products. It relates to a process for producing benzene and xylenes comprising (a) converting a plastic waste to a hydrocarbon liquid stream and a pyrolysis gas stream in a pyrolysis unit, contacting the hydrocarbon liquid stream with a hydroprocessing catalyst in the presence of hydrogen to yield a hydrocarbon product and a first gas stream, wherein the hydrocarbon product comprises C5+ hydrocarbons, feeding the saturated hydrocarbons stream to a reforming unit to produce a reforming unit product, a second gas stream, and a hydrogen stream, wherein the reforming unit comprises a reforming catalyst, introducing the reforming unit product to a second aromatics separating unit to produce a non-aromatics recycle stream and a second aromatics stream, comprising C6+ aromatic hydrocarbons, recycling a portion of the non- aromatics recycle stream to the reforming unit, introducing the first and/or the second aromatics stream to a third aromatics separating unit to produce a first C6 aromatics stream comprising benzene, a C7 aromatics stream comprising toluene, a C8 aromatics stream comprising xylenes and ethylbenzene, a C9 aromatics stream, a CIO aromatics stream, and a Cl 1+ aromatics stream, contacting the C7, C9, CIO aromatics stream, or combinations thereof with a disproportionation and transalkylation catalyst in the presence of hydrogen in a disproportionation and transalkylation unit to yield a third aromatics stream, comprising benzene and xylenes, and conveying at least a portion the Cl 1+ aromatics stream to the hydroprocessing unit. Prior art discloses conversion of plastic waste to value added products. However, none of them disclose the conversion of unsorted waste plastics to value added products such as fuels and chemicals in a single-step process.

OBJECT OF THE INVENTION

The primary object of the present invention is to provide a plastic recycling system and method, which can provide a safe and reliable environment for thermal decomposition and pyrolysis of plastic.

Another object of the present invention is to provide a plastic recycling system and method, which can generate value added chemicals through thermal decomposition and pyrolysis of waste plastics.

Yet another object of the present invention is to provide a plastic recycling system and method, in which waste plastic material of any type such as Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PET), Low Density Polyethylene (LDPE), and High Density Polyethylene (HDPE), can be used as the feed, for the generation of value added chemicals.

Still another object of the present invention is to provide a plastic recycling system and method, in which plastic material used as feed can be of any type, i.e., rigid or flexible plastic, for the generation of value added chemicals.

Further, another object of the present invention is to convert plastic wastes into hydrocarbons that can be used for specific applications. Further, yet another object of the present invention is to convert plastic wastes into hydrocarbons that can be further treated and converted into chemicals, depending on market requirements.

SUMMARY OF THE INVENTION

The present invention provides a system and method for the upcycling of plastic waste into valuable hydrocarbons which can be used directly as fuel oils or further converted into value-added chemicals. Said method involves thermal cracking or thermal depolymerization of waste plastics which could be of any type. Said waste plastic may be a plastic such as PP, PET, LDPE, HDPE and the like. The system of the present invention comprises a thermal depolymerization reactor coupled with a series of kilns, hot condensers, cool condensers, gas distributors, and receptacles to produce fuel oils or value-added chemicals. Said process does not involve use of a catalyst or external application of pressure higher than the ambient pressure.

BRIEF DESCRIPTION OF THE DRAWINGS

The summary of the present invention, as well as the detailed description, is better understood when read in conjunction with the accompanying drawings that illustrate one or more possible embodiments of the present invention, of which:

Figure 1 illustrates the schematic representation of system for pre-processing of plastic material and subsequent conversion of the pre-processed plastic material to hydrocarbons and chemicals. Figure 2 illustrates a chromatogram from the gas chromatographic analysis of sample obtained from receptacle AB.

Figure 3 illustrates a chromatogram from the gas chromatographic analysis of sample obtained from receptacle AW.

Figure 4 illustrates a chromatogram from the gas chromatographic analysis of sample obtained from receptacle AX.

DETAILED DESCRIPTION OF THE INVENTION

Various embodiments will now be described to provide an overall understanding of the principles, structure, function, manufacture, and use of the processes and apparatus disclosed herein. Those with ordinary skill in the art will understand that the features described or illustrated in connection with one example embodiment can be combined with the features of other example embodiments without generalization from the present disclosure.

The accompanying drawings, which are included to provide a further understanding of the invention are incorporated in and constitute a part of this specification, illustrate the embodiments of the present invention, and together with the description, explain the principles of the invention.

The present invention is related to a single-step reaction process for the conversion of plastic material into value-added fuel oils and chemicals through de -polymerization. Said plastic materials may include, but are not limited to, polyethylene (PE), polypropylene (PP), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), polyvinyl, or mixtures thereof. The raw materials for conversion into chemicals may also include light petroleum distillates (LDP), heavy petroleum distillates (HDP), and the like, or a mixture thereof.

Aromatics, particularly benzene and xylenes, are important chemicals, with applications ranging from chemical intermediates to solvents. Benzene occurs in crude oil and is used for manufacturing chemicals such as ethylbenzene, cumene, cyclohexane, nitrobenzene, and alkylbenzenes. Benzene has a high octane number, and is an important component of gasoline. Benzene can also be used in the manufacture of rubbers, lubricants, dyes, detergents, drugs, explosives, and pesticides.

While xylenes occur in small concentrations in crude oil, xylenes are produced mainly as part of the BTX aromatics (benzene, toluene, and xylenes). Xylenes are primarily used as solvents in various applications, such as in printing, rubber, and leather industries, and are common components of ink, rubber, adhesives, thinning paints, varnishes, and cleaning agents (e.g., for steel, silicon wafers, integrated circuits). Xylene is also used as a building block for producing Terephthalic acid (TPA) from which Polyethylene Terephthalate (PET) which is one of the most widely used plastic types in the world, is manufactured. Plastic waste is posing a big threat to humans and animals and therefore, research on the conversion of plastics into fuels and value-added products is also in progress. There are many alliances that are being formed across the globe to address the threat posed by waste plastics to the environment. These are aimed at addressing the issue through conversion of waste plastics into fuels, chemicals and energy.

The present invention is related to a system and a method for the direct conversion of crude plastic wastes into high value chemicals. According to an embodiment of the present invention, the pre-processing of plastic material comprises loading different types of plastic materials procured from various sources, into a plastic shredding machine, wherein the plastic material is ground into powder form or chips, and manually fed into a reactor kiln. Melting and gasification of said ground plastic material is performed in the same reactor kiln (C) wherein the de -polymerization takes place,

The present invention relates to a single-step reaction process for the conversion of raw, unsorted, contaminated plastic waste materials to generate fuel oils and chemicals. The type of contaminants could be of inorganic, organic or biological origin and concentration of these contaminants may vary which will have an effect on the recovery percentage or yield of chemicals.

The invention also relates to a system for plastic waste conversion comprising a series of kilns, hot condensers, cool condensers, gas distributors and receptacles. The process for plastic waste conversion comprises a de -polymerization process, wherein said plastic waste material is loaded in a de -polymerization reactor also called Kiln (C) equipped with a special heating system wherein de -polymerization takes place at a temperature of 90°C to 550°C under atmospheric pressure for 18 to 28 hours, said depolymerization process further comprising a humidity removal process, wherein said reactor kiln (C) is heated to remove the moisture present in said plastic material at a temperature of 90°C to 140°C. This is followed by a self-purging process for the removal of oxygen from said reactor kiln (C), wherein said purging activity is performed at 140°C to 220°C, using a temperature controller and thermal management algorithm operated and controlled through the Control Panel (A).

The materials then undergo a plastic material melting process, wherein said plastic material is melted at a temperature of 220°C to 290°C in said kiln (C), a gasification and cracking process, wherein said plastic melt solution is heated in said kiln (C) to effect gasification at a temperature of 290°C to 320°C, which is subsequently raised to 350°C and maintained at this temperature for a duration of 3 hours. Due to this heat transformation, the plastic material slowly melts and changes its state into a liquid. The temperature is then slowly increased from 350°C to 400°C in a phased manner and is maintained for 8 hours.

The gases containing lighter and heavier fractions ranging from C4 to C30 and higher fractions, evolve from said reactor kiln (C) depending on the composition of plastic. These flow into an intermediate cracker (D) for further gasification, and cracking wherein said intermediate cracker (D) provides space for expansion of said gases containing lighter and heavier fractions thereby preventing the formation of heavy oils, and asphalts heavier than C20, by condensing said heavy fractions into liquids. The lighter fraction containing hydrocarbons below C20 flows through said intermediate cracker (D) into the collection receptacles from where it travels to the condensation and distillation module for condensation and subsequent distillation into various liquid condensates.

Heavier fraction which turns into liquids in said intermediate cracker (D) is subjected to further heating in said intermediate cracker (D) where it undergoes further cracking into lighter hydrocarbon fractions below C20. The lighter gases rise and flow into the condensation and distillation module.

Hydrocarbon fractions in the range of C14-C20 travel through the connecting pipe from said intermediate cracker (D), condense and settle down as liquids in the receptacle (G). From said receptacle (G), the fraction lighter than C14 flows to the hot condenser (E) where the gases are allowed to expand and cool down to realize two hydrocarbon fractions ranging between C7 - CIO and CIO - C 14 which condense and settle into the receptacles (H) and (I) respectively.

From said hot condenser (E), the hydrocarbon fraction lighter than C7 flows into the cool condenser (F) where it is subjected to external cooling using a compressor (K), thereby realizing a liquid condensate fraction of hydrocarbons fraction in the range of C5 - C« which is collected into receptacle (J). The uncondensed hydrocarbon fraction with gases lighter than C5 moves further into the gas distributor (M) in which uncondensed gases lighter than C5 from within the systems is further passed through a gas bubbler (L) to a dual fuel diesel generator for co-combustion in its Internal combustion (IC) engine to generate electric power. This power is used in the premises for various purposes as ancillary power or is fed back into the system as a secondary power source.

The C14-C20 hydrocarbon condensate collected in said receptacle (G) is further passed into another kiln (P) in which the hydrocarbons are further cracked by subjecting the condensate to desired temperature settings. This is achieved by using an advanced thermal algorithm, wherein the liquid condensate is transformed into gaseous state. The gases rise through said kiln (P) to condense and settle as the heavier hydrocarbon fraction of C20 in the receptacle (Q), while the lighter fractions proceed into the hot condenser (U) for further expansion and condensation into two hydrocarbon fractions, Cis and Ci6, into the receptacles (R) and (S) respectively. The hydrocarbon fraction lighter than Ci6 moves further into cool condenser (V) and is externally cooled by a compressor (W) where said lighter hydrocarbon fraction expands, loses heat, and condenses as a liquid condensate consisting of C14 hydrocarbons in receptacle (T). Said C14 hydrocarbon condensate fraction realized from further cracking of heavier liquid condensates derived from plastic waste can directly be used as chemicals or fuels as desired. Alternately, they can be subjected to further synthesis downstream to produce value-added chemicals. The uncondensed hydrocarbon fractions that are lighter than C14 pass through the gas bubbler (X) into the gas separator (Y) from where it moves to another kiln (Z). Said kiln (Z) receives two inputs including an input of gases lighter than C14 from said kiln (P) as well as the liquid hydrocarbon condensate from a collection receptacle (H). A thermal algorithm is applied in said receptacle (H) to heat up the received inputs, further cracking them into lighter fractions to produce lighter fractions of C14 which rise through said kiln (Z) and condense into the receptacle (AA), while C13 and C12 containing hydrocarbon fraction passes through the hot condenser (AE) where it condenses into the receptacles (AB) and (AC) respectively. The lighter fractions pass through into the cool condenser (AF) where the gases are allowed to expand and cool through external cooling using the compressor (AG), allowing the gases to condense into a receptacle (AD). This liquid condensate consists of a C 10 hydrocarbon fraction. Lighter gases which do not condense even after passing through the cool condenser (AF) connected to compressor (AG), pass into the bubbler (AH) onto the gas separator (Al) from where it reaches the kiln (AJ).

Said kiln (AJ) receives two hydrocarbon fractions containing a fraction less than C10 from said kiln (Z), and the liquid condensate comprising of hydrocarbon fractions in the range of C7 to C10 collected in the receptacle (I) wherein the mixture of hydrocarbons is heated in said kiln (AJ) thus subjecting the same to further cracking into lighter hydrocarbon fractions. The hydrocarbon fraction containing CIO hydrocarbons rises up through said kiln (AJ), expands and condenses into the receptacle (AK) while lighter gases pass beyond said receptacle (AK) into a hot condenser (AO) allowing further expansion and condensation, before being collected as liquid condensates of hydrocarbon fractions of C9 and Cs into receptacles (AL) and (AM) respectively. Hydrocarbon fractions lighter than Cs flow into the (AP) where they are further expanded and cooled with a compressor (AQ) thereby condensing into a liquid condensate consisting of C7 hydrocarbons.

The hydrocarbon gases lighter than C7 pass onto the bubbler (AR) and through the gas separator (AS) into a kiln (AT). Said kiln (AT) receives an input of gases lighter than C7 from the kiln (AJ) as well as the liquid condensate hydrocarbon fractions in the range of C5 to C8 from the receptacle (J). This stream may contain benzene and small quantities of toluene and xylenes. The hydrocarbons from receptacle (J) which consist primarily of hydrocarbons in the range of C5 to C8 also consists of commercially viable molecules such as ortho-xylene, meta-xylene and para-xylene. These , heated in the kiln (AT) to further crack the same into lighter hydrocarbon fractions ranging between C5 to C8, which will be collected in various receptacles and these commercially viable hydrocarbon molecules can be recovered using distillation.

The mixture of hydrocarbons heated in said kiln (AT) is subjected to temperatures designed for cracking and subsequent separation occurs at pressure not more than the ambient pressure, thereby realizing separation of commercially viable molecules such as benzene based compounds and xylenes. The percentage of xylenes in the resultant liquids can be as high as ~27 %. This is further cracked into lighter fractions which rise up through said kiln (AT), passing through into the receptacle (AU) where C8 fractions condense into a liquid while the lighter fractions move further through the condensation and distillation apparatus into a hot condenser (AY) where the C7 and C6 hydrocarbon gases expand and condense into the receptacles (AV) and (AW) respectively, while the lighter fractions move into the cool condenser (AZ) where C5 hydrocarbon fractions are expanded and condensed with the help of a compressor (BA), and collected in the receptacle (AX).

While most quantities of xylenes are collected in Tank (AV), a small quantity of xylene is collected in tank (AW) too. The toluene concentration is found to be at a maximum of 3 % while benzene concentration is found to be 6%. The gas chromatographic analysis of samples drawn from AB, AW, and AY are presented in Figure 2, Figure 3 and Figure 4. The hydrocarbon compounds were identified based on their retention time which were compared with the retention time of hydrocarbon compounds in standard samples procured from the market. On performing gas chrmatographic analysis, the absolute xylene concentration in these samples was found to be 26.0%, 18.63% and 0.89% respectively.

The uncondensed gases pass through the cool condenser (AZ) and into a bubbler (BB) and onto a gas separator (BC) and move to a gas distributor (M) from where it reaches the diesel generator (O) through a bubbler (N) to undergo co-combustion along with diesel in the IC engine of the diesel generator to produce electricity which is used as ancillary power within the process or outside in the accompanying facility. All said kilns (C), (P), (Z), (AJ), and (AT), and the intermediate cracker (D) are cooled by said tower cooler (B) which is a heat cooling system.

This process is unique for its ability to process plastic waste, and generate desired hydrocarbon fractions which can be used as specialty chemicals, plastic intermediates or fuels or blend for fuels without using a catalyst or applying any pressure higher than the ambient pressure thereby making it cost-effective, while also being environmentally friendly. Moreover, the residual solid carbon upon the completion of the reaction can be added to the soil or converted into carbon bricks. Due to the low thermal co-efficient, the carbon bricks when used in the construction of enclosed spaces, help maintain the temperature contained in the enclosed space, thus contributing to energy savings.

The system for conversion of plastic waste to chemicals has also been designed for operation with solar energy. While the process operates directly with solar energy during day time when the sun is shining, the plant is run at night times with the help of batteries that store the power during day time. The system may also draw power from the grid during the night time, if required. Similar approach may be followed when the source of energy is wind.

According to the various embodiments of the present invention, the objects of the present invention are achieved through a system and method where conversion of plastics into chemical intermediates is achieved through de -polymerization. Plastic wastes such as polyethylene (PE), polypropylene (PP), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), polyvinyl, or mixtures thereof are passed through a series of kilns, hot condensers, cool condensers, gas distributors and receptacles. Waste plastics are first freed of moisture and oxygen, and then melted, and the molten solution is slowly heated upto 400°C. The initial fraction containing hydrocarbons below C20 is subjected to condensation and distillation. The resulting hydrocarbon fraction of C14 to C20 is then cracked. The hydrocarbon fraction lighter than C14 is further cracked and C7 to C10 hydrocarbon containing fraction is collected. C7 to C10 hydrocarbon stream is further separated into C9 and C« containing hydrocarbon streams. Lighter hydrocarbons of C5 to C7 are further collected. The absolute concentration of xylene in the stream may be as high as 26%. The single-step process for the upcycling of plastics thus generates desired hydrocarbon fractions which can be used as specialty chemicals, plastic intermediates or fuels or blend for fuels. The said process is carried out without using a catalyst or without applying any pressure higher than atmospheric pressure thereby making it cost- effective, while also being environmentally friendly.

It is to be understood, however, that the present invention would not be limited by any means to the components, arrangements and materials that are not specifically described, and any change to the materials, variations, and modifications can be made without departing from the scope described in the present invention.

Claims

A process for a catalyst-free upcycling of plastics to chemicals comprising: i) supplying plastic waste in a kiln (c); ii) subjecting to gasification in said reactor kiln (C); iii) subjecting to further gasification in an intermediate cracker (D) followed by separation and condensation of C14-C20 hydrocarbon fraction in a receptacle (G); iv) introducing C14 and lighter hydrocarbon fraction into a hot condenser (E), and condensing C7 - CIO and CIO - C14 hydrocarbons in receptacles (H) and (I) respectively; v) introducing C7 and lighter hydrocarbons into a cool condenser (F) and condensing C5-C8 hydrocarbon fraction in a receptacle (J); vi) introducing C5 and lighter hydrocarbons into a gas distributor (M) and a gas bubbler (L) of a dual fuel diesel generator; vii) introducing C14-C20 hydrocarbon fraction from said receptacle (G) into a kiln (P) and condensing C20 and higher hydrocarbons in a receptacle (Q) and introducing the lighter fraction into a hot condenser (U) for condensation to C16 and C18 hydrocarbons in receptacles (R) and (S) respectively; viii) introducing C16 and lighter hydrocarbons into a cool condenser (V) for condensing into C14 hydrocarbons; ix) introducing C14 and lighter hydrocarbons from the kiln (P) and hydrocarbon condensate from the receptacle (H) into a kiln (Z) through gas bubbler (X) and gas separator (Y); x) condensing C14 and lighter hydrocarbon fractions into a receptacle (AA), and condensing C13 and C12 hydrocarbons in a cool condenser (AF) and receptacles (AB) and (AC) respectively, and condensing CIO hydrocarbon fractions in a receptacle (AD); xi) introducing lighter hydrocarbon fractions from said cool condenser (AF) into a kiln (AJ) through a compressor (AG) and bubbler (AH); xii) introducing CIO and lighter hydrocarbons from said kiln (AJ) and said kiln (Z) to hydrocarbon fractions of C9 and C8 hydrocarbons into receptacles (AL) and (AM) respectively; xiii) introducing C7 and lighter hydrocarbon fraction into a kiln (AT) through a bubbler (AR) and a gas separator (AS), and introducing C5 to C8 hydrocarbons from receptacle (J); xiv) passing lighter fraction from kiln (AT) through a receptacle (AU) into a hot condenser (AY) for condensing C6 and C7 hydrocarbons in receptacle (AV) and (AW) respectively; and xv) condensing C5 lighter fraction in a receptacle (AX).

2. The process as claimed in claim 1, wherein plastics include industrial plastics, and municipal plastic waste.

3. The process as claimed in claim 1, wherein raw, unsorted, and contaminated plastic waste is converted to hydrocarbon liquids.

4. The process as claimed in claim 1, wherein said plastic waste comprises at least one selected from polyethylene (PE), polypropylene (PP), low-density polyethylene (LDPE), and high-density polyethylene (HDPE).

5. The process as claimed in claim 1, wherein said plastic waste is converted into hydrocarbons without applying external pressure.

6. The process as claimed in claim 1, wherein said plastic waste is converted into hydrocarbons for use as specialty chemicals, plastic intermediates or fuels.

7. The process as claimed in claim 1, wherein said hydrocarbon product comprises of 1-30% xylene.

8. The process as claimed in claim 1, wherein C5 and lighter hydrocarbons are subjected to co-combustion in a dual fuel diesel generator for conversion to power.

9. The process as claimed in claim 1, wherein residual solid product is converted into carbon bricks.

10. A system for a catalyst-free upcycling of plastics to chemicals comprising: i) a control panel (A); ii) a tower cooler (B); iii) a plurality of kilns (C), (P), (Z), (AJ), (AT) for further cracking of hydrocarbons; iv) an intermediate cracker (D); v) a plurality of receptacles (G), (H), (I), (J), (Q), (R), (S), (T), (AA), (AB), (AC), (AD), (AK), (AL), (AM), (AU), (AV), (AW), and (AX) for collecting hydrocarbon fractions; vi) a gas distributor (M); vii) a diesel generator (0); viii) a plurality of gas bubblers (L), (N), (X), (AH), (AR), and (BB); ix) a plurality of gas separators (Y), (Al), (AS), and (BC); x) a plurality of hot condensers (E), (U), (AE), (AO), and (AY); xi) a plurality of cool condensers (F), (V), (AF), (AP), (AZ), and xii) a plurality of compressors (K), (W), (AG), (AQ), and (BA).

11. The system as claimed in claim 10, wherein said control panel (A) is powered by said diesel generator (O).

12. The system as claimed in claim 10, wherein said kiln (C) is configured to receive said plastic waste for removal of moisture and oxygen, and for gasification, and cracking of gases emanating from molten plastic waste.

13. The system as claimed in claim 10, wherein said intermediate cracker (D) is connected to said kiln (C) and hot condenser (E).

14. The system as claimed in claim 10, wherein said kilns (C), (P), (Z), (AJ), (AT), and intermediate cracker (D) are cooled by said tower cooler (B).

15. The system as claimed in claim 10, wherein said receptacle (G) is connected to said intermediate cracker (D) and said kiln (P).

16. The system as claimed in claim 10, wherein said hot condenser (E) is connected to said receptacles (H) and (I) which are connected to said kiln (Z) and said kiln (AJ) respectively.

17. The system as claimed in claim 10, wherein hydrocarbons flow from said hot condenser (E) to said condenser (F) cooled by said compressor (K), and the liquid hydrocarbons are collected in said receptacle (J) which is connected to said kiln (AT).

18. The system as claimed in claim 10, wherein said cool condenser (F) is connected to said dual fuel diesel generator (O) through said gas bubbler (L), said gas distributor (M), and said gas bubbler (N).

19. The system as claimed in claim 10, wherein said kiln (P) is connected to said hot condenser (U), which in turn is connected to said receptacles (Q), (R), and (S), and thereon to said cool condenser (V).

20. The system as claimed in claim 10, wherein said cool condenser (V) is connected to receptacle (T), and cooled by said compressor (W).

21. The system as claimed in claim 10, wherein said cool condenser (V) is connected to said gas bubbler (X), said gas separator (Y), and thereon to said kiln (Z).

22. The system as claimed in claim 10, wherein said hydrocarbons flow from said kiln (Z) to receptacle (AA), and thereon to said hot condenser (AE), and said receptacles (AB) and (AC).

23. The system as claimed in claim 10, wherein hydrocarbons from said hot condenser (AE) flow into said cool condenser (AF) which is cooled by said compressor (AG), and is also connected to receptacle (AD).

24. The system as claimed in claim 10, wherein said cool condenser (AF) is connected to said bubbler (AH) and thereon to said gas separator (Al).

25. The system as claimed in claim 10, wherein gas separator (Al) is connected to said kiln (AJ) which also receives hydrocarbon fraction from said receptacle (I).

26. The system as claimed in claim 10, wherein said kiln (AJ) is connected to receptacle (AK) and thereon to hot condenser (AO) and further to said cool condenser (AP) which is cooled by said compressor (AQ).

27. The system as claimed in claim 10, wherein said hot condenser (AO) is also connected to receptacles (AL) and (AM).

28. The system as claimed in claim 10, wherein said cool condenser (AP) is connected to said kiln (AT) through said gas bubbler (AR), and said gas separator (AS).

29. The system as claimed in claim 10, wherein said kiln (AT) is connected to said receptacle (AU) and there on to said hot condenser (AY).

30. The system as claimed in claim 10, wherein said hot condenser (AY) is connected to said receptacles (AV), and (AW), and thereon to said cool condenser (AZ).

31. The system as claimed in claim 10, wherein said cool condenser (AZ) is connected to receptacle (AX), and cooled by said compressor (BA).

32. The system as claimed in claim 10, wherein said cool condenser (AZ) is connected to said gas bubbler (BB), and gas separator (BC).

33. The system as claimed in claim 10, wherein said gas separator (BC) is connected to said gas distributor (M).

34. The system as claimed in claim 10, wherein plastics include industrial plastics, and municipal plastic waste.

35. The system as claimed in claim 10, wherein plastics include raw, unsorted, and contaminated plastic waste.