WASTE PLASTIC TO FUEL PRODUCTION SYSTEMTECHNICAL SPECIFICATIONS AND OPERATIONAL REQUIREMENTS

OVERVIEW

Sepco Industries Company Limited is the proprietor, sole manufacturer and distributor of the Polypetron™ Gen. 5 Waste Plastic to Fuel Production System.

It is a turnkey solution which can be conveniently assembled onsite at any location that meets our installation requirements and complies with local regulations.

The fifth generation Polypetron™ has a capacity of producing 15,000 liters of pyrolysis crude oil per day while disposing of 20,000 kilograms of waste plastic.

Our fully enclosed system is 100% eco-friendly, releasing absolutely no pollutants into the environment, and producing zero waste matter. All byproducts not sent

to market are reusable within the production process

CORE ASSUMPTIONS

Client can secure land at which to house the plant in zones that would permit this industry. (The Polypetron™ System emits no noxious odors or fumes so can be located in close vicinity to residential areas. Operation of the equipment does not create any sound pollution either with sound levels at ≤ 120 db)

System operational 24 hours per day, seven days a week, 330 days a year.

Client can secure waste plastic raw material to meet capacity.

The waste plastic raw material has been cleaned and has a moisture content of no more than 10%.

Client can secure markets for fuel.

Client can secure necessary licenses, permissions, and meet local regulatory requirements.

THE POLYPETRON™ SYSTEM

The Polypetron™ System features a continuously operating screw-type reactor which is fully enclosed. The system is operational 24 hours per day, 330 days a year (30-35 days of ceased operation per year is required for system maintenance).

Standard configurations of our system include the PPT20 which manages 20 metric tons of waste plastic per day, the PPT40 which handles 40 tons, the PPT60 – 60 tons, and the PPT100 – 100 tons.

The system is easily scalable by simply adding production modules to the facility, so we advise clients to allow for expansion in their production plant planning and construction.

Acceptable feedstock is any type of plastic except PVC and PET plastic which are not recommended. Tire, rubber, oil sludge, and medical waste can also be used.

An additional feature of our system is that while we guarantee a yield of 15,000 liters of pyrolysis crude oil per day from 20 tons of cleaned waste plastic, uncleaned plastic can also be fed into the system. This would simply somewhat reduce yield.

THE POLYPETRON™ SYSTEM COMPONENTS AND DEVICES

The standard Polypetron™ System consists of a complete set of components to facilitate the process of converting sorted and cleaned solid waste plastic into pyrolysis crude oil. This process involves shredding the plastic, drying it, feeding it into the reactor, condensation and distillation of vaporized plastic, and channeling char and RDF (refuse derived fuel – hydrocarbon gas) byproducts back to further heat the reactor. Pyrolysis crude oil can be marketed directly or further refined to produce 70% diesel and 10% gasoline for sale, and 20% gas and char to be reused as fuel heating the reactor.

Additional core components include a Scrubber System for exhaust treatment so that nothing is released to the environment other than a minor amount of waste heat (most heat waste is put to use for drying plastic feedstock). Optional components that can be added include a Refining System to produce EN590 grade, low carbon diesel; and waste management systems for sorting and cleaning waste plastic.

OUR STANDARDIZED SYSTEM COMPONENT LIST INCLUDES:

Not included are main fuel storage tanks which can be installed, subject to local regulations. Typically, four 15,000-liter storage tanks should be onsite for each 20 tons of waste plastic managed per day.

1. Pre-treatment, Shredder, and Feeder System 2. Combustor & Reactor Chamber 3. Screw Reactor Type 4. Condenser System 5. Scrubber System 6. Cooling Tower

7. Chimney 8. Piping System 9. Electric System 10. Instrument System 11. Distillation Process

AREA REQUIRED FOR PRODUCTION FACILITY The production plant property should have a minimum land area of 3,000 square meters, although 4,000-4,500 square meters is recommended to allow for expansion.

THE POLYPETRON™ WASTE PLASTIC TO FUEL PRODUCTION SYSTEM IS HOUSED IN TWO MAIN BUILDINGS:

1. A warehouse for raw material storage and preparation with the capacity for storing three days’ supply of waste plastic feedstock (No temperature control required.) Size is dependent upon the capacity of the plant. Warehouse floor load should be approximately 1,500kg per square meter.

2. The main factory building which houses the reactor and distillation chambers (temperature control at 20-30 degrees Celsius) Please refer to building size specifications for each production model in the chart below. For the entry level PPT20, the main reactor footprint is 3.00m x 6.00m. A ceiling clearance of 10 meters is required and the building’s foundation must support a minimum weight of 3,000kg per square meter.

ADDITIONAL BUILDINGS THAT MIGHT BE NEEDED DEPENDING ON ADMINISTRATIVE AND LOGISTIC MANAGEMENT OF THE PLANT INCLUDE:

Administrative office(s). This will inevitably be needed in most cases. Offices can either be in a separate building or converted standard 40-foot container, or housed as separate rooms inside the main factory building, possibly as a mezzanine floor with windows facing the main reactor unit for efficient observation and oversight of equipment and staffs.

Living/resting quarters, restrooms, dining areas, conference rooms etc.

Storage/maintenance room(s).

Vehicle garage(s) for trucks, forklifts, etc.

SAMPLE FACTORY LAYOUT PLAN

FOR THE PPT20 POLYPETRON™ WITH EXPANDABILITY

TO THE PPT40

FUELING THE SYSTEM The reactor unit is heated to high temperature in order to melt down and cause plastic to evaporate before being distilled as fuel. Recommended fuel to heat the reactor is firewood. This is the most economical option in our prototype system. Other possible heating fuels are gas, other fossil fuels, or coal.

ENERGY CONSUMPTION The entry level PPT20 model requires 1.75MW of thermal energy per hour. Once operation has been initiated, it is assumed that heating of the reactor will ideally be structured using a combination of gas and char residue from the process, supplemented by biomass in the form of wood pellets.

The gas and char byproducts of our process can account for around 50% of the fuel required to heat the reactor. Consequently about 21 MWt of heat per day will be provided from external sources. Each ton of waste plastic can yield 4.8MWt of heat. Therefore 4.7 tons of biomass (wood pellets) per day will be required. Electrical power consumption starts at 55KW per hour for the PPT20, and goes up to 150 KW/h for the PPT100 model.

MANPOWER REQUIREMENTS For full-fledged operation of a basic PPT20 Polypetron™ production module, required manpower is as follows:

Plant Manager: 1 (semi-skilled) Assistant Plant Manager: 1 (semi-skilled) Electrical and Mechanical Technicians: 3 (semi-skilled) Factory Staff: 3 (unskilled) Raw Material Preparation and Handling: 3 (unskilled)

This is a total of eight persons for operation of machinery and the whole industrial process, facilitating fulltime 24-hours a day operation (three eight-hour shifts).

Depending on location, scale and local requirements, additional staff might be needed for security and janitorial work, but assigning the general maintenance and upkeep of the factory grounds and maintaining order should be able to be managed by existing staff. Basic personnel needed would include clerks/accounting staffs to handle all financial bookkeeping as well as inventory, purchasing, sales, communications, etc.

Full-fledged corporate operation would require additional positions to be filled, of course. This would depend a lot upon scale and magnitude of operations, company structure, financial management, marketing model, raw material sourcing, etc.

QUALITY OF FUEL PRODUCED

Our pyrolysis crude oil is equivalent to fuel oil which can be used as is for heavy machinery. For refining into diesel, our pyrolysis oil is superior to light crude oil in that it yields 70% EN590 grade, low carbon diesel, whereas light crude oil typically produces only about 55% due to substantial bitumen content.

Case studies of the use of our fuel by bus companies, refineries, and agricultural industry, has rendered a satisfied response from customers who have found our diesel to be of high quality. Independent laboratory test results of our fuel released by Intertek and Chulalongkorn University are attached as an appendix to this document.

FUEL OUTPUT MARKETS

The primary fuel produced by our system – pyrolysis crude oil – can be sold to petroleum companies and distributors in the open market to be refined according to their formulae. There is high demand in such markets especially with recently adopted European Parliament regulations requiring the inclusion of at least 1.5% “advanced biofuel” in all fuel sold by 2021, and 10% in by 2030. Waste-based fossil fuel (which is what pyrolysis crude oil is) is stated as a good example of advanced biofuel.

Alternatively, our fuel can be sold directly as fuel oil for heavy machinery, or further refined as diesel for retail to public or niche markets, such as transport companies, train companies, airlines, logistics companies, generating facilities etc. The supplementary 10% of gasoline produced by the process can also be sold or used internally to offset energy costs.

WARRANTY AND SERVICE

Sepco Industries Co., Ltd. shall oversee all aspects of the construction, setting up, and commissioning of the Polypetron™. Furthermore, Sepco will provide comprehensive onsite and offsite training of all operators of our system to ensure extensive smooth operation.

Sepco guarantees all components of the Polypetron™ to be free of defects and offers a complete conditional warranty of the system for a period of 1 year from the date of commissioning.

Our stated Service Life Expectancy of the Polypetron™ is 10-15 years, but actual service life is expected to extend well beyond that. Our first generation Polypetron™ has maintained operation for more than 15 years. System maintenance and spare parts replacement are offered at reasonable cost throughout equipment lifespan.

INTERNATIONAL STANDARD COMPLIANCE

The Polypetron™ is compliant with numerous international regulatory standards, including BS, EN, DIN, ASMT, etc.

BASIC PARAMETERS OF THE POLYPETRON™ WASTE PLASTIC PYROLYSIS SYSTEM

Model

Daily Plastic Waste Management Capacity

Product Pyrolysis Crude Oil - Tons

Working Method

Raw Materials

Number of Reactors

Pattern

Heating Materials

Total Electrical Power

Thermal

Land Area

Floor Area

Roof Area (L*W*H)

Operating Pressure

Cooling Method

Service Life

PPT20

20 Tons

Screw-Type Reactor: Fully Continuous

Waste Plastic, Tire, Rubber, Oil Sludge, Medical Waste

2x8 sets

Horizontal Screw

Coal, Charcoal, Wood, Fuel Oil, Natural Gas, LPG, RDF, etc.

55kw/h

1.75MW

3,000SqM

30X25m

20X15X10m

Water Cooling

Normal Pressure

10-15 Years

16,940.10

PPT40

40 Tons

33,880.20

80kw/h

3.25MW

3,000SqM

35X25m

25X15X10m

PPT60

60 Tons

50,820.40

120kw/h

4.75MW

3,500SqM

40X25m

30X15X10m

PPT100

100 Tons

84,700.60

150kw/h

7.85MW

4,500SqM

56X25m

46X15X10m

4x8 sets 6x8 sets 10x8 sets

Product Pyrolysis Crude Oil - Liters

14.15 28.29 42.44 70.73

2.83 5.66 8.49 14.15 Product: Solid (Char) – Tons

1.89 3.77 5.66 9.43 Product: Gas – Tons

Size of Reactor (Diameter x Length) 0.30X4.00m

DIESEL AND BYPRODUCT OUTPUT WITH OPTIONAL DISTILLATION SYSTEM INSTALLATION

Product (Liquid): Diesel – Liters 11,858.08 23,716.17 35,574.25 59,290.42

Product (Liquid): Benzene – Liters 1,711.43 3,422.87 5,134.30 8,557.17

Product (Solid): Char – Tons 0.99 1.98 2.97 4.95

Product: Gas – Tons 1.41 2.83 4.24 7.07

OIL RATIO OBTAINED FROM VARIOUS RAW MATERIALS BY THE POLYPETRON™ SYSTEM

Raw Material Oil Ratio

PE 50%-75%

PP 50%-75%

PS 50%-75%

ABS 40%

Plastic cable 80%

Plastic bag 50%

PVC Not Recommend

PET Not Recommend

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