Pyrolysis Plant

PYROLYSIS PLANT CONVERTS USED WASTE RUBBER TYRES & ALSO WASTE PLASTIC INTO PYROLYSIS OIL (FURNACE OIL), CARBON BLACK & HYDROCARBON GAS

Meaning of Pyrolysis
Pyrolysis(from Greek word. pyr - fire, heat and lysis - decomposition, decay) The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and size of tyres (car tyres, truck tyres, 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 in tanks as a Fuel-Oil (Furnace Oil).

Advantages of pyrolysis plants

Purest quality of pyrolysis oil( Furnace oil) as good as finished product The only commercial waste tyre process that in reality removes both worn/waste rubber tyres waste chain, in this process achievement will have significant environmental and profitability impact Both rubber tyres & plastic can be used as raw material but not simultaneously Batch & Continuous type of pyrolysis process Breakthrough technologies used to improve safety, profitability & ease of operation More than 90% of machinery parts are non-moving: this reduces the recurring maintenance.

Pyrolysis Reactor

Features of the plant: 1. 100% wastage tyre recycling is achieved (No churn left after the 2. process) 3. No chemical ingredients are used in process (environment friendly) 4. During and after the process; no soil, water or air pollution is observed. Creates economically valuable products out of wastage tyres (These are an industrial product that have a good market value and demand) 5. The most cost-effective wastage tyre recycling technology in the world. 6. Raw material (wastage tyre) is cheap and easy to provide. These are the by-products of tyre production. 7. Each recycled ton of tyres preserves 10 tons of CO2 that is a major green house gas. 8. It is a 100 % pollution free process, thus making eco-friendly environment. 9. The process can be applied to all rubber based materials. 10. The system creates an alternate source of energy to replace petroleum products and natural gas 11. System gives the opportunity to governments and local administrations to deal with the wastage tyre problem to a great extent. 12. The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and size of tyre (car tyre, truck tyre, etc.). 13. 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.

Technical Details
This is a batch process system. The wastage tyres are feed 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.

Technical Details
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 recirculated through process. These systems can be operated 12 Hours/300 Days.

The Products obtained fall into the following bands

1) FUEL OIL (Furnace Oil) (approx 35-40%) Furnace Oil is produced by this conversion plant is widely used for industrial and commercial purposes as fuel such as hot mixed plant for road construction & Fuel for Furnace in Iron smelting plants. The oil is approx 35% of the amount of feed stock.

2) CARBON BLACK (approx 35-40%) Carbon Black is also a product conversion by pyrolysis technology. The amount of recycled carbon black is approx 35% (depending on the type of tyre) of the feed stock. Presently in India Royal Carbon Black Pvt Ltd (Hanil Era Textile Group) has set up plant of huge capacity. Carbon black can be used as raw material to make bricks mixing it with Coal Ash and other value additions are easily possible could be considered at later stage.

3) STEEL WIRE (approx 10-12%) Tyres also contain steel wires up to 10%, which can be extracted after the process or it can removed before the process thru a Bead Wire removing Machine, and later the tyres could be cut in multi pieces for feed stock, benefit of this would be more realization of steel & maximum use of plant capacity

4) GAS (approx 15-20 %) Non-Condensable gases arise during the recycling application which; Has a higher calorific value compared to natural gas, can replace natural gas and propane when stored can be used as energy resource in gas burners, also used in pyrolysis system. The volume of gas generated thru this system is 15 to 20% of the total amount of recycled tyres and considering if we process 10 ton scrap tyre/day, the facility generates 1400 1500 m/day gas which has an enormous energy potential when evaluated.

Used tires

Tire Feeding

Cut System machine

Pyrolisis

Distillery

Purifying Carbon Black

Fine Carbon Black

Steel Scrap

Diesel

Gasoline

Fuel Oil

Rodrigo Triana

INDUSTRIAL PROCESS FLOW CHART

STEEL SCRAP 15 %

storage of intermediate processing product Conveyor belt

Cutting & Slicing System

storage of used tires Pyrolisis DIESEL 65% CRUDE OIL 35%

Distillation

GASOLINE 15% FUEL OIL 12%

Gas 7.5% GAS 10%

Carbon Black 40%

OTAL CONTROL PANEL PLANT

Fine Carbon Commercial Carbon Carbon black Coarse Pyrolityc carbon black

Carbon Purification System

Pyrolysis tyre machine ConfigurationLN2800 * 6600 10-12 MT Capacity

1. Pyrolysis reactor, 2.8 diameter*6.6m length, 16mm thickness 2. The cover 2mm 3. Sub-air package (good oil and heavy oil separator), 900mm diameter*1500mm, 6mm thickness 4. Oil gas cooling system : The cooling system is a big pool with 14 coiled pipes and four dampers tanks inside or Condenser & cooling tower) (108 type pipe. It is better to cool the oil gas than others) 5. Light oil tank, 1400mm diameter*3500mm length, 4mm thickness 6. Heavy oil tank, 700mm diameter*1500mm length, 4mm thickness 7. Water sealing tank (safety system), 900mm diameter*1500mm length, 4mm thickness 8. Gas combustion system (including the air blower, gas guns), etc

Pyrolysis tyre machine ConfigurationLN-2800 * 6600

9. De-dusting system: sulfur removal system (3) with sprinkler head desulphurization, 1000mm diameter*3000mm length, 6mm thickness 10. Draft fan, 7.5kw 11. the speed reducer, 5.5kw 12. The electric control cabinet 13. The heating chamber and burners 14. The Magnetic rings 15. Waste gas collecting system 16. Chimney, 5 meters lengths 17. Water pump, 1.5kw

Pyrolysis tyre machine ConfigurationLN-2800 * 6600

18. oil pump, 1.5kw 19 spiral carbon black discharge machine length of 5 meters (for additional it is 160 USD/meter 20 vacuum pump 21 hot air stove 22 carbon black cover door

Waste tires cutting machineThe processing: first cut the waste tires into circle with cutting circle machine, then cut into bars with bar cutter, finally cut it into cubes with cube cutter.
1. Cutting Circle Machine 2. strip cutting machine

3. Cubic pieces cutting machine

Steel Wire Separator before pyrolysis

Capital investment in USD (all prices are FOB Lianyungang port, China)
Price of the plant
To be paid in India

45,000
4000

Auto Feeder
Pressure Ball Valve

1000
600

Steel wire puller machine 1500 after the pyrolysis process

Capital investment in USD (all prices are FOB Lianyungang port, China)
Steel Wire Separator before pyrolysis Cutting tyre into circle machine a Cutting tyre into strip machine Cutting tyre into pieces machine Grand Total 6100
2000

3500
3500 67200

Terms & Condition

Delivery Time : 30 days from your order confirmation Installation Period : 30 days Warranty Period : 1 Year After Sales Service : 1st Year Free Service after then AMC Based. Installation, Training : Engineer will visit India and install ( to be paid by the buyers 2 way air tickets, Lodging and boarding and salary of 50 USD per day for 30 days) Other Arrangements to be made by Buyer: Storage tank of oil (Available locally), Civil Work etc