POLYCRACK Technology
What is POLYCRACK Technology?
POLYCRACK is the world’s first patented heterogeneous catalytic process that converts multiple types of waste (feedstock) into valuable hydrocarbon liquid fuels, combustible gas, carbon powder, and water.
Unlike older waste-treatment methods that require strict sorting, POLYCRACK is incredibly versatile. It can be fed a mixed variety of waste simultaneously, including:
- Un-segregated Municipal Solid Waste (MSW) with high moisture content.
- All types of plastics and petroleum sludge.
- E-waste (electronic waste) and automobile parts.
- Organic waste, such as bamboo, agricultural residue, and garden waste.
How Does POLYCRACK Work?
Conventional dry-cell batteries (like the standard AA batteries used in clocks or remotes) contain hazardous chemicals and heavy metals (such as lead, mercury, or potassium hydroxide) to act as the electrolyte.
- The Natural Electrolyte: The Aloe Ecell completely replaces these toxic chemicals with the herbal extract of the Aloe Vera plant.
- The Mechanism: The natural acidic and moisture-retaining properties of the Aloe Vera gel allow it to act as an excellent natural electrolyte. When the gel interacts with the eco-friendly metal components inside the casing, it generates a steady flow of electrons, providing a reliable and safe electrical current.
Useful Outputs and Products
A true zero-discharge technology, POLYCRACK ensures that every part of the garbage is converted into something valuable:
- Light Diesel Oil (LDO): The primary output is a combustible liquid oil that can be sold to industries to light heavy furnaces and boilers.
- Hydrocarbon Gas: The non-condensed combustible gases generated during the process are safely captured and routed back into the machine to provide the heat necessary for the 450°C reaction. This makes the plant completely self-reliant for its energy needs, drastically reducing operating costs.
- Carbon Powder: The solid residue left behind is carbon powder, which is safely sold to construction companies for manufacturing bricks.
- Clean Water: The moisture in the garbage is recovered as clean, distilled water, which is reused for the plant’s cooling systems or nearby horticulture.
Major Advantages Over Conventional Methods
POLYCRACK offers revolutionary advantages over traditional incineration (burning) or landfilling:
- No Pre-segregation Required: There is no need to manually separate wet waste, dry waste, or plastics before feeding it into the machine, saving massive amounts of labor and time.
- High Moisture Tolerance: It can process waste with up to 50% moisture. Therefore, there is no need to dry the garbage in the sun before processing.
- Zero Pollution: Because the waste is instantly reformed chemically rather than biologically, there is no rotting, no biological decomposition, and no toxic atmospheric emissions.
- Small Footprint: It requires significantly less physical land area compared to sprawling conventional landfill sites.
Real-World Application: Indian Railways
India is actively adopting this indigenous technology to manage industrial waste. A historic milestone was achieved in January 2020, when Indian Railways commissioned its first-ever Waste-to-Energy plant using POLYCRACK technology.
- Location: The plant was installed at the Mancheswar Carriage Repair Workshop in Bhubaneswar, Odisha (under the East Coast Railway zone).
- Impact: It has a capacity to process 500 kg of daily scrap and garbage generated by the railway workshop and station. Instead of sending this scrap to a landfill, the railways now produce their own Light Diesel Oil, earning revenue and completely neutralizing their waste footprint.
