{
    "title": "Catalytic conversion of plastic to fuel",
    "inventor_name": "Alka Zadgaonkar",
    "publication_year": 2005,
    "device_name": "Plastic-to-Oil conversion plant",
    "goal": "Convert non-biodegradable plastic waste into liquid hydrocarbon fuels (diesel, petrol) and useful gases.",
    "problem_addressed": "Plastic waste pollution and shortage of affordable fossil fuels.",
    "concept_summary": "A continuous industrial process that thermally cracks shredded plastic mixed with a small amount of coal in the presence of a proprietary zeolite-based catalyst, producing a high-yield liquid fuel fraction (~85 %) and a gaseous fraction (~15 %). The process is operated in a sealed stainless-steel reactor with temperature control, condensation, and gas-handling units.",
    "detailed_description": "The plant uses a cylindrical stainless-steel vessel equipped with a pressure gauge, timer and temperature sensors. Plastic waste (~=90 % of feed) is shredded, mixed with coal (~=10 % of feed) and a secret chemical catalyst derived from a faujasite zeolite, pseudoboehmite alumina, polyammonium silicate and kaolin clay. The mixture is heated anaerobically (electrically or by coal combustion) to temperatures sufficient for catalytic cracking. Vapours pass into a condenser where liquid hydrocarbons are collected; non-condensable gases are routed to a gas-meter or used for electricity generation. Solid coke remains as residue. The plant currently processes 10 t d^-^1 of plastic, with plans to scale to 25 t d^-^1, yielding 10 000-25 000 L d^-^1 of fuel.",
    "category": "Chemistry & Chemical Processes",
    "principles": [
        "Catalytic cracking",
        "Thermal pyrolysis",
        "Anaerobic heating",
        "Zeolite catalysis"
    ],
    "scientific_domains": [
        "Chemical Engineering",
        "Chemistry",
        "Environmental Science",
        "Energy Engineering"
    ],
    "mechanisms_of_action": [
        "Thermal decomposition of polymer chains",
        "Catalyst-mediated bond scission",
        "Hydrocarbon reforming",
        "Coal co-feeding for hydrogen supply"
    ],
    "materials": [
        "Faujasite zeolite",
        "Pseudoboehmite alumina",
        "Polyammonium silicate",
        "Kaolin clay",
        "Stainless steel",
        "Coal",
        "Various plastic polymers (PET, PVC, ABS, etc.)",
        "Water (for catalyst slurry)"
    ],
    "energy_sources": [
        "Electrical heating",
        "Coal (as internal fuel for co-feeding)"
    ],
    "inputs": [
        "Shredded plastic waste",
        "Coal",
        "Catalyst (zeolite-based)",
        "Water (for catalyst preparation)"
    ],
    "outputs": [
        "Liquid hydrocarbon fuel (diesel, petrol range)",
        "LPG-range gases",
        "Solid coke"
    ],
    "claimed_performance": "100 % conversion of plastic waste; 85 % of feed mass becomes liquid fuel, 15 % becomes gases; 1 kg plastic + 0.1 kg coal yields ~1 L fuel.",
    "experimental_evidence": "Pilot plant in Butibori processes 10 t d^-^1 of plastic, producing 10 000 L d^-^1 of fuel; demonstrations performed in Delhi, Mumbai and Pune; Indian Oil Corporation R&D certified the process; patent filed (WO2005094990).",
    "replication_status": "Process demonstrated in a continuous industrial pilot plant; certified by Indian Oil Corporation; multiple independent demonstrations reported.",
    "keywords": [
        "plastic waste",
        "fuel conversion",
        "catalytic cracking",
        "pyrolysis",
        "waste-to-energy",
        "liquid hydrocarbons",
        "LPG"
    ],
    "related_technologies": [
        "Pyrolysis of plastics",
        "Catalytic cracking of polymers",
        "Waste-to-energy plants",
        "Plastic recycling"
    ],
    "controversy_level": "medium",
    "confidence_score": 0.85,
    "practicability_score": 0.7,
    "fringe_score": 0.2,
    "evidence_strength": 0.6,
    "risk_score": 0.2,
    "trl_estimate": 6,
    "source_urls": [
        "http://mangalorean.com/news.php?newstype=local&newsid=38714",
        "http://www.tribuneindia.com/2003/20030928/spectrum/main4.htm",
        "WO2005094990",
        "WO02061015"
    ],
    "organizations": [
        "G H Raisoni College of Engineering",
        "Indian Oil Corporation",
        "State Bank of India",
        "World Intellectual Property Organization"
    ],
    "applications": [
        "Industrial diesel and petrol supply",
        "Agricultural pump fuel",
        "Marine fuel",
        "LPG substitute for boilers"
    ],
    "limitations": [
        "Current plant capacity limited to ~25 t d^-^1",
        "Requires coal co-feeding, adding logistics",
        "Catalyst preparation involves multiple steps and calcination"
    ],
    "open_questions": [
        "Long-term durability and regeneration of the catalyst",
        "Full emissions profile and compliance with environmental regulations",
        "Economic competitiveness at large-scale commercial deployment"
    ],
    "red_flags": [
        "Claims of zero pollution without detailed emission data",
        "Potential undisclosed by of coke and gases"
    ],
    "evidence_quotes": [
        "The plant devours a whole range of plastic waste ... and converts it 100 percent into liquid hydrocarbon fuels (85 percent) and gases (15 percent).",
        "The Indian Oil Corporation (IOC) has recommended use of the Zadgaonkar liquid fuels in running agriculture pumps and boilers, as marine fuel and input feed for petro refineries.",
        "The only scientist from India to attend the Global Plastic Environmental Conference (GPEC) - 2004 ... Alka has been approached by the Japanese oil giant Izemitsu, the US Applied Science Inc. and Germany's Marlos Thormann Energy Solutions with tie-up offers.",
        "About 1 kg of plastic and 100 gm of coal churn out a litre of fuel, which contains the gasoline range."
    ]
}