Now in Nagpur: Fuel from plastic waste

NAGPUR: Fuel from plastic waste is a reality — a commercial reality.  The Unique Waste Plastic Management and Research Company Pvt Ltd of Dr Alka and Umesh Zadgaonkar, is producing 5,000 litres of fuel from plastic trash and running a profitable business of selling it to industrial units in Butibori, outside the city.

Away from the public gaze and doubting Thomases after their public claims in 2003, the Zadgaonkars have been producing fuel from plastic waste since March this year. If they have not made a noise about it, it’s because they are drowning in business enquiries and expansion plans. By December, they want to expand capacity five-fold to 25 MT  of plastic waste (25,000 litres daily) — and ultimately grow it to 450 MT.

The couple set up the plant at the industrial estate here in 2004 with a Rs5.5 crore loan from the SBI. Industrial units in the area are running their captive power plants on this fuel and are happy with its pricing and performance. The Zadgaonkars’ fuel (it’s not yet been given a name) is priced at Rs30 per litre, Rs8 less than diesel.

Though it is not yet vehicle-ready, the fuel scores over petrol/diesel because it ignites  faster. Besides, several test reports by government and non-government institutions say it has smaller sulphur content and low reaction temperature. Above all, the Maharashtra Pollution Control Board has found that the conversion of plastic waste into fuel is non-polluting.

Engine output is nearly as much as produced by other fuels. A test drive on a Kinetic Honda gave a mileage of 44 km/ltr on plastic fuel as compared to 44.4km/ltr on petrol. It accelerated from 0 to 60 km in 18 secs against 22.5 secs on petrol.

“We can’t imagine a day without plastics. So why not convert it into something more useful?” asks Alka. And for the Maharashtra government, which has announced a near-impossible-to-implement ban on plastic, here’s a good reason to rethink the ban.  

Facts

*Zadgaonkars’ plant went into commercial production in March 2005

*Producing 5000 litres fuel from 5MT of waste daily

*Fuel has not yet been given a brand name

*Presently can be used for seven functions such as running gensets

*Can also run vehicles after more refining. Has better combustibility than petrol

*Bike did 0-60 in 18 secs on this fuel against 22 secs on petrol

The journey from lab to plant

2000: Dr Alka Zadgaonkar, an applied chemistry professor from Nagpur, invents a catalyst that can convert plastic waste into fuel in her lab.

2001: With husband Umesh, Alka files for national and international patents.

2003: Government of India invites Alka to demonstrate her invention in New Delhi. She does so successfully. Ties up with Indian Oil Corporation for further testing and fine tuning the product. But fresh from the Ramar Pillai con job (where he fooled the nation with his claims of extracting petrol from water), there is heavy scepticism about their claim.

2004: Zadgaonkars decide to drop out of limelight. Set up a plant for commercial production at Butibori industrial estate outside Nagpur with a Rs5.5 crore loan from SBI. Go about their job without attracting much attention from media or scientific tribe.

2005: By early March they start producing 5000 litres of fuel. Are selling it to about 30 units in the MIDC area for running captive power generators. The most critical stage of all inventions—commercial viability—is established.
Even SBI in its project review report praises the couple for running a profitable business. Now plans are underway to up production five times by December.

State govt takes note. Signs up with the couple to develop the market for the fuel through the Maharashtra Energy Development Agency. MEDA is flooded with enquiries from private energy firms within and outside country.