Please read carefully as we fully explain the concerns.
In recent years, public awareness of waste plastic or used motor oil as a fuel resource has lead to some creating YouTube websites showing how to build a back yard refinery to convert (distill) plastic or oils into flammable liquid fuels. Refinement of volatile fuels is an extremely hazardous process...
The primary reason publishers on YouTube do this is to gain veiwership, likes, subscriptions and income on their YouTube channel, appearing to present a value to unsuspecting viewers. They are not concerned with the outcome to others who might attempt the process. The invitation to "supposedly" make cheap diesel fuel or gasoline in this way holds the appearance of value but at the untold serious hazards to those who might attempt it without the proper education in both chemistry and engineering.
Volatile distillation SHOULD NEVER be done absent the proper knowledge of the exact chemistries involved or how to build refinement systems designed to run safely and reliably among proper ventilation and heating, in an positive ventilated setting and explosion safe design and environment. And yet, we see back yard enthusiasts trying this time and again, mostly without much success, but many times with serious outcomes to those unsuspecting.
The reason we post this warning is to provide public awareness of those hazards. For those who choose to ignore the concerns, we hope to provide at least a basic understanding of the seriousness so the unsuspecting can make a more informed decision and choose not to make these attempts lacking sufficient experience. Carbon Analytic openly and expressly disclaims any liability for those who undertake refinement experiments for any reason. Below, we carefully explain exactly why.
Refinement is a serious and risky process. The creation of volatile liquids from any source carries risks of exposures including toxicity, burns, very serious fires or explosions not to mention critical environmental damage. The worst of the concerns are that back yard experimenters succeed in creating liquid fuels and gaseous byproducts but fail to realize the risk of harm to themselves or others, including family members, friends, pets or others who attempt refinement but especially those who use those fuels. Some of the most serious risks come from handling liquids or breathing toxic fumes emitted by burning and using these incomplete refinement fuels exposing themselves additionally to long-term risks of cancer or organ failure.
Environmental: It seems to make sense helping the environment by collecting used oil or waste plastic to save money on commercial fuels. Refinement of waste plastic is a rich source of energy, but is it the kind of energy we want? ONLY if it can be properly and safely refined and used in a manner to avoid toxic emissions and greenhouse climate impact, otherwise the effort actually ends up making all the current concerns WORSE. Incomplete refinement and the burning of those products actually releases more harmful exposures to the environment and humans than the solid plastic or waste oil caused.
How refinement works: Refinement of heavy fuel resources involves heating the material to create a thin liquid, bringing it past the liquid boiling point then condensing the lighter vapors into collection vessels for further refinement or use. We call this "distillation". In most cases the desire is to obtain a form similar to common diesel fuel or gasoline. Unfortunately some combinations of hydrogen, carbon and other contaminates in certain oils and plastics form complex toxic structures which do not break down in the first or second distillation "fraction". In fact, some of them cannot be broken down at all without extreme temperature and / or catalytic processes to separate and control those toxic risks correctly. Failure in this manner results in invisible toxic gaseious emissions when exposed to combustion during use. This makes the concerns of mowing the lawn or running farm implements on these fuels VERY dangerous from hidden exposures.
The byproducts of poorly controlled refinement create intermediate gasses which include vapors or liquid separated as Xylene, Toluene, Acetone, Methane, Carbon Monoxide and others just to name a few common intermediates. When these gasses are created in a poorly made distillation unit, some of the gasses will escape over hours of processing time, exposing anyone in the area breathing the fumes if not wearing chemical respirators designed for aromatic vapors. Contact with skin and hands when handling results in immediate absorption by pours in the skin, reaching blood flow, resulting in toxic exposure to the liver and kidneys minimally.
Refinement of heavier fuel sources, both bio-sources and fossil sources, must be done with carefully controlled temperatures managing between 500-700 degrees Fahrenheit (260-370 Celsius), each refinement fraction having it's own temperature range within those limits. When these temperatures are not maintained reliably, the resultant fractions will not accurately separate the values, resulting in off target hydrocarbon chains remaining bound with the desired fuels. During batch operations, several fumes will be released from the vessels. Some of these are lighter than air, some heavier than air. This means without proper ventilation a cloud of combustible fumes will develop across the floor and / or ceiling and will disperse throughout the space where they collect. Any spark or open flame will sooner or later result in these vapors igniting with incredible explosive energy release and extreme temperatures. Many times it is the act of inhaling when a flash flame event occurs causing the victim(s) to inhale combusting flames which irreparably injure lung tissue, most times leading to death.
The temperatures indicated above are greater than the durable temperature of most mild steels such as common drums or other vessels are made of. These higher temperatures result in ferrous metals oxidizing and giving up Iron oxide into the fuel, while over time thinning the thickness and durability of the vessel walls. The vessel becomes subject to rupture or loss of seal inviting fumes to be produced over the distillation time of several hours. This is referred to as "metal fatigue". Specially made vessels and plumbing should be made of the appropriate stainless steel grades and thickness, with proper build and assembly procedures to insure reliability from leakage or failure.
Not all plastics are suitable for refinement which can result in very toxic and explosive potentials or cross reaction events to take place. Vinyl, PVC, Nylon and several others which end up in mixed waste collections create these serious outcomes when not discovered and removed in preparation. There is no way to determine these mistakes once the material has been granulated. The toxic effects include run-away chlorine clouds, formaldehyde exposures and others too complex to detail here.
This page has been a summary of the more serious risks of improper distillation procedures and exposures. The items discussed are not all inclusive and are only a small part of the total risk envelope exposures in refinement. For those who intend to proceed regardless, one should consult first with those having qualified, graduate academic credentials in both organic chemistry as well as mechanical engineering. These are the minimal recommendation for design and operation of volatile refinement. Beyond this, an environmental specialist experienced in fuels confinement and fire risk mitigation needs to be included in order to avoid an outcome of run-away fire, explosions or serious environmental concerns like toxic release to local ground water following any significant accidental event.
Bear in mind the size of the refinement does not reduce the degree of risk, which is why smaller installations built by hobbyists less knowledgeable have a higher frequency of hazardous events, than commercial refiners.
