SEPTEMBER : 2011

Pre

Bringing You & Technology Together

- Project Report
For

Power Generation from Scrap Tires

Aakash Impex

Company Profile: Aakash Impex with its unique renewable technology has come up with a concept of setting new standard in renewable energy that includes using of waste tyres as a raw material and producing green fuel oil, carbon black, steel and gas. With global warming and utilization of rubber, it has now become necessary to recycle the waste and convert it in fuel oil in such a way that it is environment friendly. This is a unique technology and can be change energy market scenario in a big way. Aakash Impex has a team of experienced and expert recycling, consulting and marketing Professionals that work hard for obtaining renewable energy from the waste. Our professionals have worked in different countries. We are also working in the sector of laser systems, solar panel, and textile andan construction business. World Market ScenarioScenario:

Billions of wastages are available in all over the world. We cant burin or landWe fills that tyres due to pollution problems. There is no any other use of these waste tyres. So, we at Aakash Impex have found a solution for this wastage tyre. We separate all content from wastage tyres and make it complete renewable process.

100% wastage tyre recycling is achieved (No churn left after the process) No chemical ingredients are used in process (environment friendly) During and after the process; no soil, water or air pollution is observed.

Features of the plant:

Creates economically valuable products out of wastage tyres (These are

an industrial product that have a good market value and demand) The most cost-effective wastage tyre recycling technology in the world. Raw material (wastage tyre) is cheap and easy to provide. These are the by-products of tyre production. Each recycled ton of tyres preserves 10 tons of CO2 that is a major green house gas. It is a 100 % pollution free process, thus making eco-friendly environment. The process can be applied to all rubber based materials. The system creates an alternate source of energy to replace petroleum products and natural gas. System gives the opportunity to governments and local administrations to deal with the wastage tyre problem to a great extent. The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and size of tyre (car tyre, truck tyre, etc.). During the process different vacuum values are applied in pre-determined temperatures and in different phases. Different gases are obtained and the condensed gas is stored as a fuel-oil in tanks.
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The Perfect Solution (Pyrolysis Process):

Pyrolysis is the decomposition of organic compounds under oxygen free (anaerobic) atmosphere that produces gas, oil, carbon black and steel. Efficient industrial Pyrolysis is a process to treat the rubber and industrial plastic wastage as well. As a result of pyrolysis of wastage tyres one obtains,

FUEL OIL (40% to 45%)

The main oil product produced by our recycling application is the fuel oil that is wide used for industrial and commercial purposes. The oil has 40% to 45% of the amount of recycled scrap tyres, which will be carried with licensed tanker trucks.

CARBON BLACK (30% to 35%)

Carbon Black is the main product recycled by Pyrolysis technology. The amount of recycled carbon black is 30% to 35% (depending on the type of tyres) of the total amount of scrap tyres recycled in the system. Carbon black is used as raw material or main ingredient in many industries and the chemical structure of carbon black strengthens, lengthens the endurance, and improves the coloring features of the materials. Carbon black produced by Pyrolysis process (CBp) is more economical compared to carbon black produced primarily from petroleum and is more price-efficient to be used as an ingredient in the industries listed;

Electric cable jacketing Conveyor band Carrier Bands Hose and doormat Black nylon bag Rubber additive Automotive spare parts Heat isolation Black colorant in rubber materials Plastic pipes Industrial rubber products Fire fighting

Non-Condensable gases arise during the pyrolysis process. There areCondensable

STEEL WIRE (10% to 15%)

some advantages such as..

Tyres contain steel wires and the amount range of 10% to 15% of the total tyre wastage All of the steel present in the tyre can be detachedwastage.teel after the Pyrolysis recycling process is completed. Valuable steel wires It has higher are pressed and sold to steel and scrap dealers. calorific value as compared to natural gas.hergas

GAS (10% to 12%)

It can be replaced where natural gas and propane are stored.

The high energy gas may be utilized as a source of energy for the Pyrolysis process. The amount of gas generated in the system is 12% to 15% of the12 total amount of recycled tyres and considering the 10 ton scrap tyre/day recycling capacity, the facility generates 1200 -1500capacity,12 m/day gas which has an enormous energy potential whengas, evaluated.
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Technical Detail:
This is a batch process system. The wastage tyres are fed into the reactor vessel and heated under controlled conditions of temperature and pressure. The process will bring about molecular restructuring of the rubber under the pyrolysis process as the result; furnace oil in gaseous form is produced along with other gases. These vaporized gases are passed through heat exchanges, where in the furnace oil is condensed into liquid form. During the process, carbon black and steel are also generated. The heat exchanger uses coolant water, as a condensing medium and this water is re-circulated through process. These systems can be operated 24/365.

Process Flow Chart:

Technical Parameter of Prolysis Plant :

Project ( Dimension : 6.0 *2.2 m )
Sr. No.
1 2

Equipment
Equipment Model Material

Specification
AZ - 999 Waste tyre, Rubber, Plastic & life garbage Horizontal tyre revolves About 10 tons 40%-45% 30%-35% 10%-15% 12%-15% Normal 0.4 RPM Coal, Wood, Gas, Oil About 15 HP. For 10 MT. Water Cooling Cyclic Internal Gear Drive Direct With Foundation Intermittent Operation 2600X6000 ( 10 MT.) About 8000 Kg. About 30 MT

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Structure Capacity For One Batch Oil Yield Carbon Black Steel Wire Gas Work Pressure Main Engine Rotation Speed Fuels Choice Power Cooling Method Cooling Water Consumption(T/H) Type Of Drive Heating Method Type Of Installation Operating Mode Reactor Dimension (MM) (Long*Diameter) Reactor Weight Total Weight

FINANCIAL ASPECTS OF THE PROJECT :

Land Requirement Construction Shade Water Requirement Power Requirement Manpower Requirement 1500 Square meters 600 Square meters

Approx. 100 Liters per day 15 Hp 1 Managers, 2 Technical, 5 Workers

Estimated Operational Cost and Return on Investment: For 10 M.T. Capacity

The analysis is based on the conjecture of 10 tons/day capacity unit operating for 300 days a year; Raw material waste Tyre : 10 ton per day*300 days = 3000 ton/ year.

Total output:

Carbon black (35%) Furnace oil (40%) Steel (12%) Gas (13%)

1050 Ton (Rs 8000 per Ton in India) 1200 Ton (Rs 28000 per Ton in India) 360 Ton (Rs 15000 per Ton in India) 380 Ton (We are not considering price of it right now)

CAPITAL INVESTMENT : PARTICULARS Land & Building Pyrolysis Plant Price Pulvelizer for Carbon Black Oil Storage Tank, Crusher Foundation & Electric Connection Magnetic Filter Cotton & other item Separator Tyre Cutter Trolley (With Scooter Tyre ) Weight Machine D.G. Set Working Capital QUANTITY INVESTMENT 1 1 1 1 1 1 1 1 3 1 1 1 As per Rent Rs. 45 Lacks Rs. 6 Lacks Rs. 4 Lacks Rs. 5 Lacks Rs. 4 Lacks Rs. 0.60 Lacks Rs. 1.20 Lacks Rs. 0.24 Lacks Rs. 0.08 Lacks Rs. 4.25 Lacks Rs. 15 Lacks

TOTAL ( A )

Rs. 85.37 Lacks

INTEREST AND DEPRICIATION :

PARTICULARS Interest on Capital Investment @ 15 % Per annum ( Excluding Land & Building )

AMOUNT Rs. 12.80 Lacks

Depreciation on Machineries @ 15 % Per annum TOTAL ( B )

Rs. 12.80 Lacks Rs. 25.60 Lacks

EMPLOYMENT COST : PARTICULARS Managers Technical Workers TOTAL ( C ) NOS. 1 2 5 MONTHLY SALARY Rs. 0.25 Lacks Rs. 0.15 Lacks Rs. 0.06 Lacks ANNUAL SALARY Rs. 3.0 Lacks Rs. 3.6 Lacks Rs. 3.6 Lacks Rs. 10.2 Lacks

PRODUCTION COST ( BASED ON 10 TONS/DAY & 300 WORKING DAYS/YEAR ) : PARTICULARS Waste tyres ( 10 Tons x 300 Days ) Employment cost (C) Fuel for initial firing Electricity + Water Misc. Expenses Rent TOTAL ( D ) 12 Month QTY 3000 Tons / Year 450 Tons woods/Year PRICE Rs. 7000 / Ton Rs. 5000 / Ton Approx Approx Rs. 25000 TOTAL AMOUNT Rs.210.0 Lacks Rs. 10.2 Lacks Rs. 22.5 Lacks Rs. 10.0 Lacks Rs. 12.0 Lacks Rs. 3.0 Lacks Rs. 267.7 Lacks

REVENUE ( INCOME ) GENERATION :

Volume of waste tyre processed per year : 3000 Tons

PRODUCT Carbon Black Furnace Oil Steel Wire Gas TOTAL ( E )

% OUT PUT 35 40 12 13

OUT PUT ( TONS ) 1050 1200 360 380

PRICE / TON Rs. 8,000 Rs. 28,000 Rs. 15,000 Us in D.G.

TOTAL INCOME Rs. 84 Lacks Rs. 336 Lacks Rs. 54 Lacks .. Rs. 474 Lacks

PROFITABILITY :

PARTICULARS Production Cost ( D ) Income ( E ) Gross Profit ( E D ) Interest and Depreciation ( B ) Net Profit (Gross Profit Int. & Deprc. B )

AMOUNT Rs. 267.7 Lacks Rs. 474.0 Lacks Rs. 206.3 Lacks Rs. 25.6 Lacks Rs. 180.7 Lacks