Authors :
Dinesh U.; Vasanth M.; Vignesh S.; Yuvaraj S.; Dinesh P.
Volume/Issue :
ICMST-2025
Google Scholar :
https://tinyurl.com/m7s6se9r
Scribd :
https://tinyurl.com/mw7e22ud
DOI :
https://doi.org/10.38124/ijisrt/25nov757
Abstract :
The exponential increase in plastic production and consumption has caused a serious global environmental
challenge due to the non-biodegradability and long persistence of polymeric materials in ecosystems. Conventional
methods of waste plastic management such as landfilling, incineration, and mechanical recycling are no longer sufficient to
handle the growing volume and diversity of plastic waste streams. Consequently, alternative approaches that integrate
environmental sustainability with energy recovery have become imperative. One of the most promising strategies is the
conversion of waste plastic into liquid fuel through controlled pyrolysis, a thermochemical decomposition process that
occurs in the absence of oxygen. This paper presents an extensive study and engineering development of a Waste Plastic to
Fuel Conversion Unit, integrating thermochemical analysis, process design, catalyst optimization, and artificial intelligence
(AI)-based control modeling. The research emphasizes the influence of process variables—temperature, residence time,
catalyst selection, and feedstock composition—on fuel yield and quality. Additionally, a computationally aided process
optimization framework employing artificial neural networks (ANN) and genetic algorithms (GA) has been developed to
predict and enhance fuel conversion efficiency. Experimental and simulation results confirm that the optimized process
achieves a conversion yield of up to 82%, producing a hydrocarbon-rich liquid fuel with calorific values comparable to
commercial diesel. The proposed unit demonstrates an economically viable, environmentally safe, and scalable pathway
for converting non-recyclable plastic waste into useful energy resources.
Keywords :
Plastic Waste Management, Pyrolysis, Renewable Fuel, Process Optimization, Waste-To-Energy, Catalyst, Artificial Intelligence, Sustainability.
The exponential increase in plastic production and consumption has caused a serious global environmental
challenge due to the non-biodegradability and long persistence of polymeric materials in ecosystems. Conventional
methods of waste plastic management such as landfilling, incineration, and mechanical recycling are no longer sufficient to
handle the growing volume and diversity of plastic waste streams. Consequently, alternative approaches that integrate
environmental sustainability with energy recovery have become imperative. One of the most promising strategies is the
conversion of waste plastic into liquid fuel through controlled pyrolysis, a thermochemical decomposition process that
occurs in the absence of oxygen. This paper presents an extensive study and engineering development of a Waste Plastic to
Fuel Conversion Unit, integrating thermochemical analysis, process design, catalyst optimization, and artificial intelligence
(AI)-based control modeling. The research emphasizes the influence of process variables—temperature, residence time,
catalyst selection, and feedstock composition—on fuel yield and quality. Additionally, a computationally aided process
optimization framework employing artificial neural networks (ANN) and genetic algorithms (GA) has been developed to
predict and enhance fuel conversion efficiency. Experimental and simulation results confirm that the optimized process
achieves a conversion yield of up to 82%, producing a hydrocarbon-rich liquid fuel with calorific values comparable to
commercial diesel. The proposed unit demonstrates an economically viable, environmentally safe, and scalable pathway
for converting non-recyclable plastic waste into useful energy resources.
Keywords :
Plastic Waste Management, Pyrolysis, Renewable Fuel, Process Optimization, Waste-To-Energy, Catalyst, Artificial Intelligence, Sustainability.
