Nurulmasitah 55221119079 Intrareport
Nurulmasitah 55221119079 Intrareport
Nurulmasitah 55221119079 Intrareport
SDN. BHD.
I declare that all parts of this report are the result of my own work except for the quotations
and references.
i
This report was read and verified by:
14/10/2023
(MOHAMAD ASHRAF ZULNIZAM)
Date
Company Supervisor
ii
ACKNOWLEDGMENT
I begin by thanking Allah for His divine wisdom and mercy, which have led me to
Mensilin Green Energy Sdn. Bhd. @ Syngas Sdn. Bhd for this internship. I am profoundly
thankful for the chance to learn, grow, and contribute to the betterment of society through
this experience.
First and foremost, I would like to thank UniKL Malaysian Institute of Chemical and
BioEngineering Technology (MICET) for facilitating this internship opportunity and for
their commitment to fostering student development through such experiences. Next, I would
like to extend my heartfelt thanks to Mohamad Ashraf Zulnizam, my supervisor, for the
guidance, mentorship, and unwavering support throughout my internship. I am also grateful
to the entire team for welcoming me with open arms and making me feel like a valued
member of the team from day one. The collaborative and inclusive environment at Syngas
Sdn. Bhd has fostered my personal and professional development, and I am genuinely
appreciative of the camaraderie and support I received from my colleagues.
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ABSTRACT
The principal fuels utilized in all automation systems around the world are diesel,
petrol, kerosene, naphtha. Given that existing fuel manufacturing is not ecologically friendly,
the potential of the Syngas Plastic-To-Fuel machine to manufacture fuel is consistent with the
company's claim of providing green energy.
The PTF Conversion system provides an integrated plastic waste processing system as
a realistic, affordable, and environmentally responsible alternative to landfill disposal,
incineration, and recycling. The Syngas Plastic-to-Fuel Conversion Plant provides an
effective, cheap, and environmentally responsible alternative to the present recycling and
disposal of plastic waste. The Syngas Plant is constructed in a way that allows for modular
construction. A single module can generate up to 80% of the fuel oil required for every tonne
of typical plastic waste processed. Plants can process 5 tonnes to more than 100 tonnes of
plastic garbage each day. The ratio of plastics feed and diesel produced 1:1. Which mean 1 kg
of plastics feed will produce 1 litre of oil. By adding more modules, the overall capacity of
the plant can be easily increased. Hence, excellent quality Sulphur Low Cetane
Environmental Technology Diesel oil is a type of fuel oil that is manufactured.
Since, there are a few of problems during the production, the machines are still in the
research and development stage for almost 14 years. One of the major issues is the irregular
rate of evaporation, which has adversely affected the machine's expected output. The current
test unit should receive 40 kg of plastic waste every hour, or one tonne of plastic waste per
day. Various types of plastics with varying densities, such as, High Density Polyethylene
(HDPE), Polypropylene (PP), Polyethylene terephthalate (PET) and Polystyrene (PS) will be
analysed to study the characteristic of products. The materials affect the rate of evaporation,
which affects the output differently. Adjustments will be made using the information in
accordance with the materials being used. The project must be run several times using
various materials and a different machine in order to meet its objectives. Although the project
was still on going, the trainee has gained valuable working experience and managed to
complete the industrial training report.
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TABLE OF CONTENTS
DECLARATION.......................................................................................................................i
ACKNOWLEDGMENT........................................................................................................iii
ABSTRACT.............................................................................................................................iv
CHAPTER 1: INTRODUCTION...........................................................................................1
3.2 Expectation...................................................................................................................10
4.1 Conclusion......................................................................................................................20
4.2 Recommendation............................................................................................................20
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REFERENCES.......................................................................................................................21
APPENDIX.............................................................................................................................21
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LIST OF FIGURES
vii
LIST OF TABLES
No. of Table Title Page No
viii
CHAPTER 1: INTRODUCTION
1.1 Objectives of Industrial Training
Students of UniKL’s diploma and degree programmes, must perform Industrial Training
(INTRA) in order to compete the study. Students from Bachelor of Chemical
Engineering with Honours must perform a 10-week internship at any company related to
their degree. However, the internship can be extended to 12 weeks depending to the
company. Each student will require supervision from the university and appointed firm
supervisor in order to guide and assist their allocated assignments.
The objectives of internship can vary depending on the specific organization, field of
study and trainee’s personal goals. For this INTRA, the objectives are listed below:
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1.2 Industrial Training Location
The trainee completed her industrial training at Syngas Sdn. Bhd., a fully owned subsidiary
of Mensilin Green Energy Sdn. Bhd (MGE). A factory called Syngas Sdn. Bhd. produces
plastic into diesel. The factory is located at Gong Badak, Kuala Terengganu, Terengganu.
The distance from the trainee’s house to the factory is 8.1 km and takes 11 minutes to arrive.
The picture below shown the location of the factory
The trainee was assigned as Production Intern at Syngas Sdn. Bhd. in Research,
Development, and Operation department. The chemical engineer, Mr. Mohammad Ashraf
was in charge of all aspect of research, development and operation. All the task that need to
be done was assigned by him.
During the internship, a lot of tasks were assigned to the trainee. The primary task for
his team was to produced 20000 litre/month diesel for company located at Thailand. Hence,
this project included the trainee to assist with the production of diesel, including monitor
temperatures data, machine maintenance and outstation work to collect four types of plastics.
The maintenance included, clear Reactor 1 from hard wax and plastic cokes. Also, changed
water filter, remove the residue in reactor 1 and lastly shape and moulded catalyst.
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CHAPTER 2: COMPANY OVERVIEW
Kejuruteraan Yuhana Sdn Bhd, founded in 1984, was renamed Mensilin Green Energy Sdn
Bhd (MGE) in 2014 with the ambitious goal of pursuing Renewable Energy and Energy
Efficiency projects, specialising in active and passive energy conservation measures for
commercial and industrial buildings and facilities. In order to implement its diversification
strategy, MGE purchased 100% of Syngas Sdn. Bhd.'s shares in 2017.
Syngas Sdn Bhd is a company that produced diesel oil from plastics. The Syngas
Conversion Machine (PTF) transforms waste plastic into diesel oil and ultra-low sulphur
diesel fuel. PTF Technology registered with the Malaysia Commissioner of Patents and Trade
Marks (MyIPO) on January 30, 2014, with registration number MY-150550-A. PTF has also
been granted worldwide patents in 60 countries.
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Figure 4: P&ID for Plastic-To-Fuel Machine
• Feedstocks are inserted into the extruder through the feeding system.
• The extruder screws will be tightened up and push the feed to the RT1.
• The load in the RT1 will then evaporate to the catalyst chamber 1 and be
collected in tank 1 as heavy fuel oil (HFO)
• The process continues from tank 1 as the liquid flows into Tank 2 through a
connector.
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• Then, it will be collected in tank 2 as Diesel, and some of it will condense
through condenser 2 and be collected as Light Fuel Oil (LFO) in a collection
tank.
Syngas Sdn. Bhd.'s aim is to provide a healthier living environment for the next generation,
as stated in their mission statement, "building a brighter future."
Its primary goal is to turn trash into highly marketable green renewable energy sources such
as petrol, diesel, kerosene, naphthalene, ethanol, and methanol.
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2.4 Occupational Safety and Health
Occupational safety and health (OSH) are vital in industries such as diesel production
because workers are exposed to a variety of possible dangers. A complete approach is
required to ensure the safety and well-being of employees in a diesel production facility.
Hence, Syngas Sdn. Bhd. assure everyone in the production area to wear appropriate
PPE, such as safety goggles, gloves, flame-resistant clothing, and respiratory protection, as
necessary to mitigate specific hazards. Other than that, diesel production involves various
machinery and equipment. Regular inspections, maintenance, and guarding of moving parts
are essential to prevent accidents. Next, while handling highly flammable fuel, adequate fire
prevention measures must be in place, such as fire suppression systems, extinguishers, and
emergency evacuation plans.
Furthermore, employees must wear safety helmets because they are the first line of
protection against head injuries when worn properly. The safety helmet aids in the prevention
of item penetration and the absorption of shock from strikes. The aim of the double strap is to
tighten the safety helmet when it is worn. Employees are required to wear safety helmets in
the factory since there is a forklift and they work at heights. Safety boots are essential for
preventing or, at the absolute least, decreasing the severity of foot injuries while working.
Steel-toed safety boots help prevent injuries by lowering the danger of slips, falls, and
accidents caused by falling objects.
Industry Solutions for Syngas Waste Plastic-to-Diesel Fuel will serve the following sectors:
• Agricultural Waste
• Auto Salvage Yards
• Material Resource Facilities
• Military Bases
• Waste Management Companies
• Waste Recycling Companies
• Waste to Energy Projects
• Municipal Waste Facilities
• Retail and Fast-Food Chains
• Waste Collection Companies
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2.6 Awards and Recognition
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2.7 Syngas’s Product and Price Range
Table 2: Syngas's product range
PRODUCT RANGE
• Technologically advance oil that helps high accelerating
engines achieve optimum power and performance at
high speed without compromising protection.
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• Heavy Duty Grease is a heavy-bodies product. It is
ideal for tractor track rolls and all type of agricultural
• equipment construction machinery, machine tools,
fifth wheel, logging equipment and fresh salt water
dredges.
PRICE RANGE
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CHAPTER 3: TECHNICAL OVERVIEW
3.1 Role of Unit
On her first day, the trainee was assigned to the Research, Development, and Operations
department at the Terengganu factory, and her company supervisor is Mr. Mohamad
Ashraf Zulnizam. At this company, the trainee is responsible for monitoring and
recording the data generated by the Plastic-To-Fuel machine every hour. She must then
participate in the creation of the diesel by weighing the product and pouring it into the
prepared diesel tank. My colleagues and I are occasionally required to perform machine
maintenance, primarily for Reactor 1 and Reactor 2. The procedure involved removing
the residue in Reactor 1, opening the gaskets in Reactors 1 and 2, and measuring the
remaining system in Reactors 1 and 2. Other than that, the trainee was assigned to apply
rock wool at Reactor 2 to maintain the temperature. Next, the student also involved to
welcome the visitors and need to do plastic waste characterisation study at Sungai Kandis,
Selangor.
3.2 Expectation
The company can expect certain things from an intern after the completion of their
internship. Firstly, they can anticipate that the intern will be receptive to feedback and
open to constructive evaluation of their performance during the internship. This
willingness to learn and grow is an essential quality in any prospective employee.
Additionally, the company can expect that the intern will maintain and nurture the
professional relationships they've established during their time at the organization.
These connections could prove valuable for future collaborations or networking
opportunities. Furthermore, the company can reasonably hope that the intern may
speak positively of their experience and provide references or recommendations if
they are satisfied with the intern's contributions. While offering a full-time position
may not always be possible, the company can expect that the intern will leave with
enhanced skills and experience, which could potentially make them a more attractive
candidate in the job market. Ultimately, the company can look forward to the intern
continuing to grow professionally and potentially becoming an asset to the
organization in the future.
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3.3 Schedule of Training (Gantt Chart)
Figure 4 below shows a Gantt Chart for overall process throughout industrial training at
Syngas Sdn. Bhd.
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3.4.1 Assist in Diesel Production
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Extruder temperature was set to 270°C in Zone 1 and increased
by 10 degrees in each following Zone until Zone 9. Next, the
temperature had to be monitored and recorded every one hour
The plastic pellets were feed into the hopper when the
hopper sounds the alarm. The maximum weight at one time
is 10 kg. The plastic pellet used are HDPE.
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Took the discharged product from the Plastic-To-Fuel machine
which is diesel and weighed the product using a loadcell. Lastly,
the diesel were store in IBC tank.
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3.4.2 Machine Maintenance
During the production of the diesel, supervisor and trainee observe the machines to
make sure the diesel produced was sufficient to the plastics pellets input. However, the diesel
produced were not match the amount of plastic pellet feed into the hopper. The temperature
of Reactor 2 was increase slowly. The leaking at extruder were occur due overflow. Hence,
the production of the diesel was stop to continue with machine maintenance.
Then, the gasket on Reactor, the pipe connecting Reactor 1 to Rector 2 must be
opened to know any clogs at that area. Hence, the plastic wax was found clog in metal pipe
connecting Reactor 1 and Reactor 2. Therefore, the trainee needs to dug out the plastic wax
using chisel and other tools.
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After that, the trainee together with other colleagues continue to clean out plastic cokes in
Reactor 1. From that, answer for temperature drop can be identified since the plastic cokes in
Reactor 1 can reduce the efficiency.
Other than that, the trainee also assisted in changing water filter from cooling tower. The
trainee noticed the induction sound an alarm before suddenly shut off. Therefore. The trainee
decided to change the water filter.
After that, during the second batch of diesel production, the supervisor noticed that
temperature at Reactor 1 drop and the diesel produced were not sufficient. The trainee was
asked to clear the residue in Reactor 1 together with engineers. Hence, the production once
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again must be stop to identify the problems. Therefore, the gasket of Reactor 1 was opened
and noticed Reactor 1 were full with plastic wax at top. Then, plastics wax again been clean
out. Next, when the plastic wax had been cleaned out at top o reactor, the colleagues noticed
that the bottom part of Reactor 1 filled with plastic cokes. The plastic cokes were dug out abd
crushed to clean the Reactor 1.
Figure 12: Hard plastic wax Figure 13: Plastic cokes at the
at top of Reactor 1 bottom of Reactor 1
Then, the trainee was asked to install rock wool at Reactor 2. The rockwool was used as
insulation. Insulation is crucial to prevent heat loss in Reactor 2. Also, insulation can
decrease the energy demands of heating or cooling systems. The temperature of Reactor 2
must be maintained between 300°C - 350°C.
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Figure 14: Rockwool installed around Reactor 2
On the last day of internship, trainee assisted in disassembling Reactor 1. This is due to the
condition of the reactor were not efficient to produce diesel since its was used at a long
period. The reactor will be installed with the new one.
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3.4.3 Assist Visitors from Indonesia and University Malaya
Syngas Sdn. Bhd. won third place in television reality programme called “Inovathon”. Rafizi
Ramli, Minister of Economy, and Chang Lih Kang, Minister of Science, Technology, and
Innovation, have been named to a permanent jury. Therefore, the company had been
recognised by others company and investors. Then, Syngas Sdn. Bhd. had been welcoming
visitors. Hence, the trainee was assigned to clean the factory. From that, the trainee learned
on how to great the visitors and improved communication skilled.
On the second week of September, the trainee together with other colleagues were assigned
to do an outstation work at Sungai Kandis, Selangor. The aim this project was to collect 30
kg of each type of plastics. The plastics include, High Density Polyethylene(HDPE),
Polypropylene(PP), Polyethylene terephthalate(PET) and Polystyrene(PS). The plastics
wastes were collected at waste trap around Sungai Kandis. Additionally, the wastes are going
to use to examine the characteristics of oil produced.
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CHAPTER 4: CONCLUSION AND RECOMMENDATION
4.1 Conclusion
In conclusion, the internship at Syngas Sdn. Bhd. was a rewarding experience that extended
student's horizons and provided the opportunity to gain valuable skills and insights.
Throughout this time, the student had the honour of working with a dedicated team of
specialists who graciously offered their knowledge and guided me through numerous
responsibilities. Furthermore, the company provided students with the opportunity to operate
the Plastic-To-Fuel machine in order to develop problem-solving skills that would be useful
in the industry in the future. Following that, the student was able to apply some of the
theories acquired in class to his work at the factory. The collaborative environment enabled
her to contribute to relevant projects, improving the practical abilities and broadening
the knowledge of the diesel production sector. This internship has also emphasised the
necessity of adaptability and effective communication in managing real-world difficulties,
and grateful for the assistance and mentorship the student received during her time here.
4.2 Recommendation
Recommendations for Syngas Sdn. Bhd. internship programme include numerous key
elements to improve the overall experience for future interns. First and foremost, an
organised and well-defined internship programme that clearly defines intern tasks and
responsibilities, as well as the precise learning objectives they are expected to complete, is
essential. This structure provides a firm foundation for interns to develop their talents and
make a meaningful contribution to the organisation.
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REFERENCES
APPENDIX
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Figure 20: Flow of PTF technology
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