Applied research · KhNU

Smart system for thermochemical conversion of polymer waste into fuel with energy-autonomous solar power

We are building a compact unit that turns plastic and rubber waste into liquid motor fuel. The reactor is heated by induction, solar panels with batteries supply the energy, and a digital control system automatically selects operating modes for each type of feedstock.

Experimental unit with solar power supply and induction heating.

Research area Safe, clean energy and energy efficiency	Thematic area Renewable energy sources, circular economy
Technology readiness TRL 3 → TRL 5–6 from laboratory proof of concept to validation in a near-real environment	Institution Khmelnytskyi National University
Project leader Eduard Manziuk DSc (Eng.), Professor, Department of Computer Science	Principal investigator Valerii Martyniuk DSc (Eng.), Professor, Head of the Department of Automation, Computer-Integrated Technologies and Robotics

Interdisciplinary project

The project brings together six fields. Chemistry and ecology define what to process and how, energy and mechanical engineering provide the unit, and computer science is responsible for what makes the system “smart”: control, models, optimisation and data.

Leading role

Computer science

Intelligent process control, mathematical models, mode optimisation, monitoring and research data management.

Automation and computer-integrated technologies

Industrial controller, temperature, pressure and gas composition sensors, heating control, emergency protection.

Renewable energy

Photovoltaic system, batteries, inverter and the balance between generation and consumption.

Chemical technology and engineering

Kinetics of polymer thermal degradation and fuel quality: density, viscosity, fractional composition, sulphur content.

Ecology

Impact of polymers on soil, water and air, environmental criteria for fuel and emission cleaning.

Machines, apparatus and materials science

Reactor design, thermal calculations, conversion of solid residue into sorbents.

What computer science does in the project

Digital control system

Software for a Siemens SIMATIC S7-1200 industrial controller: PID temperature control, adaptive heating power control, emergency protection.

Adaptation to feedstock

Algorithms that adjust temperature, reaction time and heating intensity to the type of waste on their own.

Energy management

An algorithm that balances solar generation, battery charging and reactor consumption so the unit can run autonomously.

Real-time monitoring

Tracking of emissions (CO, NOx, SO₂, particulate matter) and temperature with automatic correction of the operating mode.

Modelling and prediction

Kinetic and CFD pyrolysis models for common polymers that predict product yield and properties.

Mode optimisation

Design of experiments and multi-criteria optimisation with genetic algorithms: balancing fuel yield, fuel quality and energy use.

FAIR research data

Experiment database, open formats, programmatic access, code in an open repository, data integrity control.

Software product

A computer program for intelligent control of the pyrolysis process with adaptive parameter optimisation.

Relevance

Plastic accumulates faster than it is recycled

415 Mt of plastic produced worldwide in 2023	9% of plastic waste from 1950–2015 was recycled
40.7% recycling rate of plastic packaging in the EU in 2022	5–7% recycling rate of polymer waste in Ukraine

Landfilling pollutes the environment for centuries, and mechanical recycling needs careful sorting and does not work for mixed waste. Pyrolysis, the decomposition of polymers by heating without oxygen, makes it possible to obtain liquid fuel similar to diesel from waste. The project addresses gaps that remain in existing solutions:

Pyrolysis units depend on centralised power grids, and solar-powered induction heating has barely been studied.
Most units lack adaptive control for the feedstock type and power supply conditions.
Solid residue and pyrolysis gases are often not utilised.
Industrial units are stationary and expensive, so small communities cannot use them.

Goal and objectives

To create an intelligent, energy-autonomous system for thermochemical conversion of polymer waste into motor fuel using high-frequency induction heating and photovoltaic power.

Analyse the environmental impact of synthetic polymers.
Study the kinetics and thermodynamics of thermal degradation of various polymers.
Develop ways to use all conversion products following circular economy principles.
Define environmental quality criteria for liquid fuel from waste.
Create a fuel quality control system that meets environmental standards.
Design and build a reactor with induction heating and digital control.
Develop an energy management system based on photovoltaic modules.
Create a system for filtering and neutralising gases.
Run tests and determine optimal operating modes.
Disseminate the results among researchers, communities, environmental organisations and industry.

How it works

From waste to fuel on solar energy

Shredded waste is heated in a sealed reactor without oxygen. The vapour condenses into liquid fuel, the non-condensable gas is cleaned, and the solid residue becomes raw material for sorbents. A digital control layer runs the whole process.

Energy

Solar panels → Inverter and charge controller ⇄ Batteries + 220 V grid backup

Process

Waste PE, PP, PS, PET, rubber → Induction heater high-frequency → Reactor oxygen-free → Condenser

Products

Liquid fuel Gas → cleaning cyclone, adsorption, catalysis Solid residue → sorbents

Control

Sensors temperature, pressure, gas composition → Controller PID + adaptive algorithms → Heating, energy balance, protection

Induction heating warms the reactor walls with eddy currents, so it heats faster and more evenly than gas burners or resistive heaters, and burns no gas.

Prototype

Earlier experimental unit

The project builds on a previously developed prototype: a mini-reactor with induction heating, powered by a solar panel, batteries and the grid, and a cooler in which liquid fuel condenses.

Induction heating control board and thermostat.

Unit with storage batteries.

Mini-reactor.	Induction coil around the reactor.
Cooler and condenser.	Liquid fuel from rubber waste.

Work plan

Four stages of research

Environmental characteristics of waste and thermochemical degradation processes. Environmental impact of polymers, decomposition kinetics, ways to use all products.
Environmental monitoring and fuel quality control. Environmental criteria, quality control protocol, process monitoring system.
Design and manufacture of the smart system. Induction-heated reactor, solar power supply, gas cleaning, testing.
Dissemination of results. Publications, conferences, seminars for communities and industry, open data.

Expected results

What the project will deliver

Energy-autonomous unit

A working model of the conversion system with induction heating and solar generation.

Digital control system

Software with adaptive algorithms for different feedstock types.

Monitoring platform

Real-time control of environmental parameters with automatic mode correction.

Mathematical models

Validated pyrolysis models for the most common polymers.

Polymer database

Classification of polymer waste by environmental impact.

Residue technology

Conversion of solid pyrolysis residue into sorbents and other useful materials.

Open science

Results in open access

Articles in open-access journals and preprints.
Datasets with persistent DOI identifiers under an open licence.
Code for control systems and models in an open repository.
Deposit in the KhNU institutional repository.
An open online course on polymer waste processing technologies and renewable energy.

Contacts

Get in touch with the project team

Project leader: Eduard Manziuk, manziuk.e@khmnu.edu.ua

Principal investigator: Valerii Martyniuk, martyniukva@khmnu.edu.ua

Khmelnytskyi National University, 11 Instytutska St., Khmelnytskyi, 29016, Ukraine