Manufacturing Alternative Fuels From Waste Plastics

We are solving the dual problem of plastic pollution and fossil fuel dependence. Estimates show that less than 5% of all plastics manufactured globally each year are recovered or recycled. The majority end up in our rivers, oceans and landfills or are used directly as a source of energy by burning thereby releasing toxic emissions harmful to agriculture, marine and human life. According to the World Bank, Nairobi City alone produces 480 tons of waste plastic every day majority of which are dumped in landfills. Further, the World Economic Forum predicts that by 2050 our oceans will hold more plastic waste than fish. On the other hand, fossil fuels which are critical to many economic sectors, exploit and deplete virgin and diminishing resources causing a negative impact on climate and exposes consumers to their volatile prices.

Unsustainable consumption and production patterns such as linear models of “take-make-dispose”, unsustainable resource extraction, fast fashion and use of plastics in consumer packaging exacerbate the plastic pollution problem.

Like many towns in Kenya, Kenol town in Murang’a County where we are based, waste plastics litter the town and its landfills yet if well harnessed this nuisance can be turned into an opportunity for affordable alternative fuel. With rising fuel costs across the globe, many businesses large and small are exploring alternative energy solutions that are both affordable and environmentally friendly, a solution we are currently offering.

We recover end-of-life plastics and through a thermochemical process of decomposition convert them into high-quality fuels that have a high-octane index, low ash and low sulfur content compared to traditional fossil fuels. The fuels are trademarked as “FUELSAV” and come in two variants: Polydiesel Fuel Blend and Polypetrol Fuel Blend. Both can be used 100% exclusively or as a blend with pump fuel in heavy diesel and mid-sized petrol engines and machinery such as 3-wheeler bikes, tractors, combines, graders, water pumps, generators etc. reducing the amount needed for same engine performance, reducing emissions and saving on fuel costs. 

To achieve this solution, we have fabricated equipment with a capacity of processing 1000kgs of plastic waste per day. It includes a reactor, a furnace, a catalytic chamber, a vaporizer, two condensers, a gas filter, a temperature control system and a collection chamber. We then use a simple distillation process to extract the polyfuel. Most importantly, to reduce our carbon footprint during the production process, we use black char from the produced after incineration to make heating blocks/briquettes which are then used to generate heat to power the reactor.

Our solution serves small business owners, farmers and manufacturers with stationary and non-stationary heavy-diesel and mid-sized engines. Currently, they depend on fossil fuels to power their engines and machinery. With increasing fuel costs and the continued impact on the climate, a new solution that is cleaner yet matches the reliability and performance of conventional fuels is needed. Our fuel addresses this need because it has been tested using internationally recognized quality standards and shown to burn better, cleaner and longer while not needing any modification or retrofitting of existing engines.

James Muritu is a proximate leader. He leads our efforts to resolve plastic pollution in Kenol town and surround areas with plans to expand to major cities and other international markets. He lives in Kenol town and for the last 3 years has conducted research, trials and experiments with local traders on a solution to the plastic menace.

Out of a staff of 9, seven live in Kenol town and are knowledgeable about local production, consumption and waste disposal patterns.

Our fuel targets small businesses and farmers operating water pumps for irrigation, generators, motorbikes, tractors etc Being a rural town featuring many of these types of users, our fuel has been collaboratively developed and tested with the communities’ input, ideas, and agendas. Motorcycle riders locally known as boda boda make up a majority of our Polypetrol fuel variant. We constantly track and incorporate their feedback to further improve our fuel quality making our solution truly driven by the local community.

• A production plant and office fully constructed and operational with capacity to process 1000kgs per week
• Our sales revenues stood at $5000 in March 2024
• Intertek – a global total quality provider has tested the fuels using the EAS177:2019 diesel standardization specification used in East Africa. On key metrics, FUELSAV surpasses traditional fossil fuels. See results here;
• FUELSAV has also been tested and certified by the Kenya Bureau of Standards and issued with a quality mark under permit number SM#71858. See below;
• We hold trademarks of our product name and logo. See it here;
• We hold a patent of our technology and process of fuel production from waste plastics. See it here;
• To comply with local environmental regulatory requirements, ProGreen Innovations was granted an Environmental Impact Assessment permit in August 2023 by Kenya’s National Environment Management Agency (NEMA). See below
• Awards and recognition – recognized by Publicis Sapient as “Community Impact Recipient”, EpiC 2024 Europe Finalist and Elsevier Foundation Chemistry Innovation Challenge.
• Production plant is operational with experienced chemical and mechanical engineers on site
• 1 petrol dispensing machine installed in partnership with a local small scale vendor to sell our fuel

• Over 100 returning customers with testimonials of a number of them documented. Mr Haron Kamau, one of our customers has had his story covered by China’s CGTN network here:
• Media coverage by 15 local and international media including AP, DW, CGTN, Reuters, Radio France International, Citizen TV Kenya, Nation media Kenya among others. Covered by UNEP in their December 2023 issue of “Environmental Highlights” for Africa Region. Find it here;

https://issuu.com/who-kenya/docs/environmental_highlights_3_12_

Below are the hyperlinks to the media features;

https://youtu.be/NJLOw9vS6OY?si=UnJBNpqI0V6EHeN-

https://youtu.be/NEFtfDYCD-Q?si=AFsOW2oDXDwq212k

https://www.energyportal.eu/news/meet-the-kenyan-man-turning-plastic-waste-into-car-fuel/344468/

https://portalnews.co/tecnociencia/keniano-logra-producir-combustible-a-partir-de-desechos-plasticos

https://x.com/RT_com/status/1711632654938825156?s=20

https://thekenyatimes.com/latest-kenya-times-news/meet-kenyan-making-petrol-and-diesel-from-plastic-waste/

https://www.africanews.com/2023/10/03/the-kenyan-entrepreneur-turning-plastic-to-fuel//

https://africanian.com/tech/from-trash-to-treasure-the-remarkable-quest-to-turn-plastic-into-fuel/

https://www.haystack.tv/v/kenyan-entrepreneur-turning-plastic-fuel

https://biznakenya.com/man-making-cheap-petrol-and-diesel-from-plastics/

https://www.onegreenplanet.org/environment/kenyan-man-turning-plastic-waste-into-car-fuel/

https://www.f6s.com/companies/climate-change/kenya/co

https://whownskenya.com/james-muritu-innovative-muranga-man-making-petrol-from-plastics/

https://www.plastnet.se/article/view/1056333/entreprenor_fran_kenya_gor_fordonsbransle_av_plastavfall

https://drive.google.com/file/d/1mrCJCBIvsc3orwIH4teAe-fQVlm8aPq/view?usp=sharing

https://drive.google.com/file/d/15kDAe5PEnacrIFmrH5Lgc8oXV3K342yY/view?usp=drive_link

https://drive.google.com/file/d/12c32UM-8u40PyM7ts10SaoEEEPxep2Nm/view?usp=sharing

https://drive.google.com/file/d/1FzPa0HI3xeSa-7lFWC4zFWcUBdw6gIo0/view?usp=drive_link

https://drive.google.com/file/d/1fUoR4Gso8ExXpLpk7nBTH80IqLW3NBwq/view?usp=drive_link

https://www.publicissapient.com/news/publicis-sapient-announces-winners-of-2023-global-energytech-awards

https://epic.hkstp.org/semi-finalists-2024/

We're thrilled to apply to Solve because we see a unique opportunity to overcome key hurdles and accelerate our positive impact. While our technology has garnered initial traction, we face challenges on several fronts:

• Market Expansion: Solve's extensive network can connect us with potential partners and investors who share our vision for a sustainable future. This will help us scale our operations and establish our solution in new markets.
• Technical Expertise: Solve's mentorship program can connect us with industry experts who can provide valuable guidance on business and technical aspects of our operations.
• Policy and Awareness: We can leverage Solve's platform to raise public awareness about plastic pollution and the potential of waste-to-fuel solutions. This can influence policy changes that create an enabling environment for our technology.

Beyond Funding: While financial support is a consideration, Solve offers a holistic approach. We believe the program's mentorship, networking, and awareness-raising opportunities will be instrumental in overcoming these barriers and propelling our solution towards widespread adoption.

Our waste-to-fuel technology tackles the plastic crisis with a novel and impactful approach. Here's how it disrupts the current landscape:

1. A Two-Pronged Attack: Unlike traditional waste management methods like incineration or landfills, we address both plastic pollution and fossil fuel dependence. We divert plastic waste, preventing environmental damage and microplastic contamination, while simultaneously creating FUELSAV - a clean-burning fuel alternative.

2. Value from Waste: Our technology transforms plastic waste, a burden on society, into a valuable commodity. This incentivizes waste collection and creates a circular economy, where plastic becomes a resource rather than a liability.

3. Modular and Scalable: Unlike large, fixed-location waste-to-energy plants, our modular design allows for easily replicated facilities which can be set-up near landfills in multiple towns which enables us to expand geographically, handle growing waste volumes, and maximize our environmental impact.

Our success can inspire a domino effect where as our technology proves commercially viable, it can incentivize other companies to develop similar solutions, creating a more robust waste-to-fuel sector. Our success story can also inform policy changes that encourage waste-to-fuel technologies and support infrastructure development for efficient waste collection and processing. Lastly, our business can attract further investment in the waste-to-fuel space, accelerating innovation and market penetration of our plastic derived fuel.

Our technology also has the potential to significantly alter the waste management and fuel industries:

• Landfills and incineration plants could become waste-to-fuel hubs, creating a more sustainable waste management system.
• Our clean-burning fuel can gradually replace a portion of the fossil fuel market, leading to a reduction in greenhouse gas emissions and a cleaner energy future.
• The widespread adoption of our technology can raise public awareness about plastic waste and the potential of sustainable solutions, promoting responsible consumption habits.

Theory: By providing a commercially attractive solution for converting waste plastic into high-quality fuel, we can incentivize widespread adoption and disrupt traditional waste management and fuel consumption practices.

Activities:

• Develop and refine conversion technology, explore diverse feedstock options, and optimize fuel quality.
• Forge partnerships: Collaborate with waste management and fuel distribution networks to secure waste plastic and market our fuel.
• Construct and scale conversion facilities: Increase processing capacity and geographic reach to maximize impact.

Immediate Outputs:

• Operational waste-to-fuel plants diverting plastic from landfills and incineration.
• Established partnerships for waste collection and fuel distribution.
• Production of clean-burning fuel blends displacing traditional fossil fuels.

Longer-Term Outcomes:

• Reduced plastic pollution: Less plastic entering landfills and oceans, minimizing environmental damage and microplastic contamination.
• Lowered reliance on fossil fuels: Decreased greenhouse gas emissions contributing to cleaner air and climate change mitigation.
• Circular economy for plastics: Plastic waste transformed into a valuable resource, promoting responsible consumption and production practices.

There is a growing body of evidence to link our innovation to its intended impact. For example:

• A study by the University of California, Berkeley titled "Life Cycle Assessment of Pyrolysis Oil from Waste Plastic as a Transportation Fuel” and published in the journal Environmental Science & Technology in 2021, found that converting waste plastics into fuel could reduce greenhouse gas emissions by up to 80%.
• A report by the World Economic Forum report, titled "The New Plastics Economy: Rethinking the future of plastics," found that the economic costs of plastic pollution could reach $2.5 trillion per year by 2025. The report also found that plastic pollution is costing the global economy $8 billion per year in lost tourism revenue.
• A study by the Massachusetts Institute of Technology titled "Life Cycle Assessment of Fuels from Post-Use Non-Recycled Plastics” and published in the journal Environmental Science & Technology in 2023 found that converting waste plastics into fuel could reduce greenhouse gas emissions by up to 80%.
• A study by the World Health Organization titled Health benefits of converting waste plastics into fuel and published in the journal Environmental Health Perspectives in 2023 found that converting waste plastics to fuel could reduce air pollution-related deaths by up to 20%.
• A report by the World Bank titled “The World Development Report 2020: Trading for Development in the Age of Global Value Chains”, found that the transition to a circular economy could create 11 million new jobs worldwide in the recycling and waste management sectors, as well as in the production and distribution of the fuel produced.

Our company is driven by the ambitious goal of creating a significant positive impact on the environment and our reliance on fossil fuels. Here's how we define and measure our progress towards these goals:

1. Diverting Plastic Waste:

• Goal: Reduce plastic entering landfills and incineration by 100 tons annually within 5 years.
• Measurement: Track the volume of waste plastic processed by our facilities and partner organizations. Partner with waste management companies to quantify the reduction in plastic waste entering their traditional disposal systems.

2. Lowering Reliance on Fossil Fuels:

• Goal: Displace 35-40% of traditional fossil fuel usage in our target markets with our clean-burning fuel within 10 years.
• Measurement: Monitor the volume of fuel produced and sold, calculating the estimated displacement of fossil fuels based on industry standards for fuel efficiency. Partner with fuel distributors to track the use of our fuel in specific sectors like transportation fleets.

3. Promoting a Circular Economy for Plastics:

• Goal: Establish a network of operational waste-to-fuel plants processing plastic waste from 15 sites in Kenya within 5 years; replicate this model within other markets outside Kenya(in Africa and Asia)
• Measurement: Track the construction and operational status of our conversion facilities. Monitor the geographic reach of our partnerships with waste management companies, demonstrating the creation of a circular economy for plastic waste within specific regions.

We collect, sort waste plastics and through a thermochemical process called pyrolysis extract polyfuels which have a high-octane index, low ash and low sulphur content from the synthetic polymers. We have fabricated equipment with a capacity of processing 1000kgs of plastic waste per week. It includes a reactor, a furnace, a catalytic chamber, a vaporizer, condensers, gas filter, temperature control system and collection chambers. We then use a simple distillation process to extract the polyfuel. Most importantly, we use black char from the production process, mixed with waste paper and biomass to make heating blocks/briquettes which are then used to generate heat to power the reactor. In this way the energy used in production is generated internally off-grid.

The process involves;

• A network of waste collectors who collect waste plastics and sell to us. We then sort them to determine the ideal types to use as feedstock for our production process. We have found High-density polyethylene (HDPE) and LDPE to be the most ideal and is a common packaging choice for consumer goods thus readily available.
• Using a shredding machine, we cut the plastics into smaller sizes
• Cleaning of shredded plastics and loading into an oxygen free reactor chamber
• Elevation of temperatures to incinerate the plastics
• Syngas control to avoid overheating
• Distillation of the resultant pyrolysis (crude) oil is then carried out at elevated temperatures to separate lighter and heavier fractions of hydro carbons present.
• Packaging and branding

Full-time - 8

Part-time - 1

2 Years of Research and Development prior to registration

11 months in operation since registration

We value a diverse and inclusive team as we strongly believe it is essential for innovation and impactful problem-solving. Here's how we cultivate an equitable and welcoming environment for all:

• Leadership Diversity: Our leadership team reflects a range of backgrounds and experiences, fostering a culture that values diverse perspectives.
• Proactive Recruitment: We actively seek candidates from underrepresented groups in STEM fields through targeted outreach and partnerships in local colleges and universities. Additionally, we utilize unbiased interview practices to minimize unconscious bias.
• Mentorship and Training: We offer mentorship to new team members to foster a respectful and inclusive work environment.
• Flexible Work Options: We recognize the importance of work-life balance and offer flexible work arrangements to remove barriers for individuals with diverse needs.

Our business model creates a positive impact on the environment while generating revenue through two key value propositions:

1. Waste Management Solution:

• Value Provided: We offer municipalities and waste management companies a sustainable alternative to landfills and incineration for plastic waste.
• Services: We collect waste plastic and convert it into high-quality fuel blends.
• Customer Benefits: Our solution reduces waste disposal costs and bolsters their sustainability efforts.

2. Sustainable Fuel Production:

• Value Provided: We offer local markets and economic sectors a clean-burning fuel alternative derived from waste plastic.
• Products: We produce high-quality petrol and diesel fuel blends.
• Customer Benefits: Businesses can potentially lower fuel costs while reducing their carbon footprint.

Revenue Generation:

• We generate revenue by selling the produced fuel to local markets and partnering fleets.

Our financial sustainability plan hinges on a diversified revenue model, with the ultimate goal of our core business operations covering all expenses. Here's how we're working towards this:

1. Selling Sustainable Fuel: Our primary revenue stream is derived from the sale of high-quality fuel blends produced from waste plastic. We target local markets, farmers and traders seeking a cost-competitive and environmentally friendly alternative to traditional fuels.

2. Carbon Markets – We are actively working towards eventually joining carbon markets to trade in carbon credits and generate an additional revenue stream.

3. Diversification of products – We are working to develop bio-fuels from biomass and commercialize our heating blocks made from a combination of black char from our plastic incineration and waste paper.

4. Strategic Investments: We are actively seeking to raise investment capital from venture capitalists and impact investors who share our vision of a sustainable future. This funding will fuel further research and development, expand our processing capacity, and accelerate our geographical reach.

Early Traction and Evidence of Success: While still in the early stages of commercialization, we've secured a total of 10 tons of waste plastic so far and converted them to over 6000 litres of fuel. Additionally, we've received good market acceptance raking in $5000 as at March 2024 demonstrating interest in our solution and validating our financial model.

As we scale our operations and establish a larger customer base, the revenue generated from our revenue streams will become the primary driver of our financial sustainability. We are confident that our innovative technology and commercially viable approach will allow us to achieve long-term financial stability while revolutionizing waste management and combating climate change.