NanoFuel Technology Inc.

The CDP "Polymer to Diesel" plant transforms mixed plastic or other materials containing hydrocarbons directly into diesel oil, using a special catalyst made of "nanoparticles". This patented process "imitates" how petroleum is naturally produced. The catalyst "cracks" the long molecular chains of the hydrocarbons and shortens them in a specific way. This process is called "de-polymerization". No dioxin, furan or other toxic products are produced, as the working temperature inside the reactor is only 300 to 350 °C. During the "Polymer to Diesel" process up to 90% of the net calorific value of the mixed polymers is retained by the high grade diesel oil.

How it works

In the initial process, mixed plastic, shredder-light fractions and other products containing hydrocarbons are freed of undesirable substances like metals, inert fillers, etc. Next the product is dried, extruded if necessary and pulverised after the addition of embrittling agents
The powder is then fed into the reactor of the CDP "Polymer to Diesel" plant and heated. The special nanocatalyst is added as soon as the material has reached the appropriate temperature. The catalyst and polymers quickly react, due to the large surface area of the pulverized material used and the polymer chains are cracked
The main product of this reaction is always diesel, because the reaction temperature of 300 to 350 °C is higher than the boiling point of diesel so that the original diesel is vaporized. Toxic products and inert fillers from the plastic and other products that have not been transformed into diesel, form a concentrate with the catalyst and are extracted from the reactor.

The following products containing hydrocarbon can be transformed into high grade diesel:

All kinds of plastic, including the PVC element
Rubber and car tyres
Oil waste, wax and all kinds of grease including transformer oil and hydraulic fluid
Agricultural waste, animal waste and spoiled food (Prions are guaranteed to be completely destroyed)
Hospital waste that has been sterilized, dehydrated and dried
Refinery waste like bitumen, tar, etc.
Organic residues
Renewable raw materials
Toxins in organic material are concentrated by and bound to the catalyst.

What the catalyst does
The specially developed catalyst of nanoparticles is the active agent. Approx. 0.5-3% of the total amount of material fed into the reactor is the catalyst.

Compounds of chlorine in the oil, which could form dioxin or PCB, are converted into salt by the catalyst.
The working temperature is lower than the temperature typically needed to generate dioxin, furan and other toxic materials. Thus the diesel is always free of toxic contamination.
Impurities and inert fillers, etc. which cannot be converted into diesel are bound to the catalyst and are extracted after use.
As the diesel product is in a gaseous form, solid or other inorganic substances contained in the material fed into the reactor cannot contaminate the final product. They are extracted at the end of the process.
All toxic fractions are absorbed by the catalyst and extracted.
The ion-exchanging catalyst is extremely active.
high yield: The diesel product retains up to 90% of the caloric value of the original material
The finished product: diesel fuel with a cetane rating >58, appropriate for diesel engines

The technical background

The "catalytic de-polymerization" technique does not change hydrocarbons with their CH₂ molecules for example into methane (CH₄) and coke crystals like other techniques do. The CH₄ molecules remain and are only shortened in their molecular length by the nanocatalyst. Solid and inorganic noxious substances cannot contaminate the diesel product, because it consists only of vaporized molecules.

Special characteristics
Waste containing PVC can be processed without difficulty. Any toxic material left over like heavy metal, chlorine, inert fillers and so on, are reliably bound to the catalyst, neutralized for final disposal and extracted with the catalyst. The moisture produced, condenses into regular water.

Special technical characteristics

Practically unpressurized operation (slight subpressure), thus no special permits required
Energetical self-sufficiency through a diesel generator utilising both the power and heat produced
Does not take up much space
Fully automatic operation
Complete material pre-treatment available

Scope of delivery
The CDP plant can be delivered as a turnkey system including complete material pre-treatment

Product range
CDP type I: capacity approx. 500 liters of diesel / h
CDP type II: capacity approx. 2,000 liters of diesel / h
Higher hourly capacities of up to 20,000 liters of diesel are available on request

Material needed for the production process
The following items are needed for running the diesel production plant:

Nanocatalyst (approx. 0.5 to 3 % of the total amount of material)
Lime (CaCO₃) or soda (approx. 1 to 5 %, depending on PVC content
The electrical and thermal energy required are produced by the diesel generator (included in the package) which combines heat and power generation. Approx. 2 to 5 % of the diesel created is necessary for operation

Comparison with other technology
Catalytic de-polymerization achieves a much higher level of efficiency compared to high-temperature technology.

High-temperature processes at more than 450°C lead to the contamination of the final product with halogenous and metallic vapours. These harmful substances generate compounds like dioxin, furan or other highly toxic chlorine, fluorine and metal compounds. These compounds have to be neutralized requiring great effort to avoid contaminating the final product.