Common Agricultural Plastics Plastofuel: The Penn State Fuel Nugget 08/2005 Two technologies join to create a way to recover heat energy from dirty, used, or non-recycled plastics The Problem… Common Agricultural Plastics HDPE (# 2): nursery pots, trays, flats, pesticide containers, drums LDPE (# 4): mulch, greenhouse covers, fumigation film, silage bags and wraps, irrigation tubing PP (# 5): row covers, nursery pots PS (# 6): nursery pots, tray inserts, flats, clamshell containers After World War II, a labor-saving agricultural technology using plastics was introduced. Termed plasticulture, the process uses film and rigid plastics to make operations more efficient, while saving time, reducing water usage, controlling weeds, and more. Although agricultural production soared, piles of waste plastic have continued to mount all over the world. The Solution… Plastofuel: The Penn State Fuel Nugget Agricultural Research and Cooperative Extension College of Agricultural Sciences A prototype machine takes waste plastics and forces them through a heated extrusion die, melting a thin jacket which locks unmelted pieces within. A hot knife cuts the extruded material into easily stored and readily shipped nuggets called Plastofuel. Plastofuel can be burned with coal in a coal-fired boiler, or eventually, combusted directly in the Korean boiler described herein. High temperature combustion (2000oF) assures clean burns with minimal emissions. The key to Plastofuel is that the production process is tolerant of dirt and debris, and since only the outer portions are melted during processing, it requires only about 1/10th the energy to form when compared to plastic pellets. As seen in the table, agricultural plastics contain a high energy value that can be used to supplement or even replace existing fuels. Material Btu/lb Fuel Oil 20,900 Polyethylene 19,900 Polypropylene 19,850 Polystyrene 17,800 Pennsylvania coal 13,900 Wyoming coal 9,600 Newspaper 8,000 Textiles 6,900 Wood 6,700 Yard wastes 3,000 Food waste 2,600 Avg. Mun. Waste 4,500 These are high-energy Plastofuel nuggets made from waste agricultural plastics. The inventor demonstrates the prototype Plastofuel machine.

Watch for our Plastofuel road show, coming to your neighborhood soon! The Solution… Technologies In 1999 in Seoul, South Korea, GR Technologies Company, Ltd. (GRT), invented a plastic-fueled burner. When paired with a hot-water boiler, the system can be used to heat greenhouses and other agricultural structures. A joint venture between Penn State and GRT will allow the Korean-built, 396,850-Btu/hr. production boiler to be tested at the Penn State Horticulture Research Farm to heat a greenhouse and high tunnel. The current unit burns 20-33 lbs. per hour of pellets made from waste agricultural plastics. The burner starts with fuel oil, and once steady conditions are reached, the fuel is automatically changed to pellets. As seen in the table, air emissions tests conforming to U.S. Environmental Protection Agency standards have recently been done. These tests were conducted by an independent test company, comparing the LDPE (# 4) Korean pellets with granulated (chopped) HDPE (# 2) discarded barrels. CEO of GRT, William Bang, has plans to commercialize the GRT system worldwide, starting in the United States. His goal is to modify the boiler to burn the more energy efficient Plastofuel. Air Emissions Note: Complete air emissions test data not available as of July 5, 2005. Coming August 2005. What’s Up Next? Thanks to financial assistance from the Pennsylvania Department of Agriculture and the American Plastics Council, the Penn State / GRT team continues to work on finding solutions. The Plastofuel machine is being enlarged to produce 500 lbs./hr. and will be installed in a trailer for travel to research and demonstration sites. The team believes that efforts started within the agricultural sector will eventually move to the rest of society, including using non-recycled plastics from consumer packaging operations. In the meantime, Plastofuel seems to be the last piece in the plasticulture puzzle. Plastics are created, serve a useful life, then continue to be beneficial in their second life. Watch for our Plastofuel road show, coming to your neighborhood soon! For Information, Contact: William Bang James W. Garthe William J. Lamont Michael D. Orzolek GR Technologies Company, Ltd. 201, Samsung Anytel Bldg. 837-17 Yeoksam-dong Kangnamgu, Seoul, 135-937, Korea Agricultural Engineer Dept. of Ag. & Bio. Engineering Penn State 246 Ag. Eng. Bldg. University Park, PA 16802 Professor of Vegetable Crops Dept. of Horticulture Penn State 206 Tyson Bldg. University Park, PA 16802 Professor of Vegetable Crops Dept. of Horticulture Penn State 203 Tyson Bldg. University Park, PA 16802 Ph: 8(223)452-9159 william@highgr.com Ph: (814)865-7118 wlamont@psu.edu Ph: (814)865-7154 jwg10@psu.edu Ph: (814)863-2251 mdo1@psu.edu Publications are available in alternative media on request. Penn State is committed to affirmative action, equal opportunity, and the diversity of its workforce.