TYRE PYROLYSIS
PLANT
REUSE
REDUCE
RECYCLE
1. TYRE PYROLYSIS PROCESS
Pyrolysis is the chemical decomposition of organic
materials by heating in the absence of oxygen or any other
reagents, except possibly steam.
Pyrolysis can be used to reprocess the tyres into fuel oil,
fuel gas, solid residue (steel wire) and carbon black.
The waste tyres are mainly composed of long chain of C-H
molecules.
Under normal process conditions the heat transfer will be
done by radiation.
The technology of pyrolysis, cracking, and monomerisation
of used tyres is always a hot topic.
2. TYRE PYROLYSIS
End-of-life tyres contain a lot of chemical bound energy.
As a result of pyrolysis of waste tyres one obtains: high-energy gas, Pyrolysis
oils, carbon black and steel wire. The ratios of the first three products depend
on process conditions, mainly on temperature.
The pyrolysis method for recycling used tyres is a technique, which heats
whole or shredded tyres in a reactor vessel containing an oxygen free
atmosphere and a heat source.
In the reactor the rubber is softened after which the rubber polymers
continuously breakdown into smaller molecule.
These smaller molecules eventually vaporize and exit from the reactor.
These vapors can be burned directly to produce power or condensed into an
oily type liquid, generally used as a fuel.
Some molecules are too small to condense. They remain as a gas, which can
be burned as fuel which can be reused in the same plant.
2. TYRE PYROLYSIS
The minerals that were part of the tyre, about 40 to 45 % by
weight, are removed as a solid.
When performed well a tyre pyrolysis process is a very clean
operation and has nearly no emissions or waste.
The properties of the gas, liquid and solid output are determined
by the type of feedstock used and the process conditions.
For instance, whole tyres contain fibers and steel. Shredded tyres
have most of the steel and sometimes most of the fiber removed.
Batch wise Process is done by tyre pyrolysis.
The steel can be removed from the solid stream with magnets for
recycling. The remaining solid material often referred to as
"charcoal".
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
WASTE TYRE AND RUBBER
PRODUCT
Nylon T.
Yre(80%).
Radial Tyre(20%).
Belt conveyor etc.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
PLASTIC MATERIAL LIKE
Waste plastic.
Electronic scrap.
Mixed Plastic (LDPE, LLDPE,
HDPE, PP, Nylon, T PS, ABS,
FRP).
Multi-layered Plastic can be
used in limited quantity.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
1. PYROLYSIS OIL
Total yield obtained: Fuel oil
- 40 to 45%.
Flash Point: 60 to 93.3 °C.
Selling price comparable to
industrial diesel LDO (light
diesel oil).
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
1. PYROLYSIS OIL USES
Furnace Industries.
Rolling Industries.
Casting Industries.
Road construction industries.
Crude oil distillation plant.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
2. CARBON BLACK
Total yield obtained: 30 to
35%.
The vital product of pyrolysis
plant is carbon black referred
as "charcoal”.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
2. CARBON BLACK USES
Cement Industries.
Ink Industries.
Rubber Industries.
Carbon briquetting Plant.
New tyre manufacturing.
Rubber runway.
Shoe sole.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
3. STEEL WIRE
Total yield obtained: 15 to 20%.
After completion of Pyrolysis
Process “steel Wire” Remains as
by Product which can be
removed by wire puller machine
after cooling down the Reactor.
Steel wire can also be removed
before adding the Radial tyre
inside the Reactor by Hydraulic
Steel Wire Removing Machine.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
3. STEEL WIRE USES
Sell to Steel scrap
Industries.
Rolling mill.
3. RAW MATERIAL REQUIRED & PRODUCT
OBTAINED
4. HYDROCARBON GAS & USES
Total yield obtained: 5 to 8%.
USES:
Generally used as a fuel in the
same plant for heating purpose.
Store in Rubber Gas Balloon and
can be used by next day process.
Used in waste water evaporating
system to evaporate the waste
water formed during process.
4. TYRE PYROLYSIS PROCESS FLOWCHART
1. Pyrolysis Oil
(Nylon/Radial Tyre)
(Fuel Oil-LDO)
Pyrolysis Process
Waste Tyre
2. Carbon
Black
3. Steel Wire
4.
Hydrocarbon
Gas
4. TYRE PYROLYSIS PROCESS FLOWCHART
1. Pyrolysis 4.
Oil (Fuel Oil- 3. Steel Wire Hydrocarbon
LDO) Gas
Pyrolysis
Recycle
Oil
Storage Burning
Storage
Unit
System
Deliver To
Compress Scrubber
Refinery
ed Unit
Unit
Transfer to
scrap Chimney
dealer
4. TYRE PYROLYSIS PROCESS FLOWCHART
2. Carbon
Black
Pulverizer
Storage Collect Sale To Market
System
Carbon Coal
Magnet & Sleeve Plant Bracketing
Machine
5. TYRE PYROLYSIS PLANT
Pyrolysis plant is renewable energy generation
system.
Pyrolysis plants are designed to generate quality fuel
from polymer waste.
Pyrolysis system or pyrolysis plant is an industry for
conversion of waste and tyre into usable products like:
1. Pyrolysis Oil (Fuel Oil)
2. Steel Wire
3. Hydrocarbon Gas
4. Carbon Black
6. ADVANTAGES OF TYRE PYROLYSIS PLANT
Purest quality of pyrolysis oil as finished product.
Use of green technology to achieve environment
friendly processes.
Automatic safely valve (pressure and temperature
valve) use to improve safely, profitability & ease of
operation.
Industry is energy self-sufficient.
No external fuel required for heating.
7. BENEFITS OF TYRE PYROLYSIS PLANT
Recover energy and value from waste in form of fuel,
steel wire and charcoal.
Reduce tyre land pollution.
Eco-friendly recycling of tyre.
Commercially viable process.
Product is used as substitute to LDO/furnace oil.
Perfect solution for polymer waste management.
Raw material available.
8. BASIC FUNCTION OF TYRE PYROLYSIS PLANT
Operating temperature of Reactor is between 300 to
350 degree c.
Duration period of pyrolysis batch is between 10 to
12 hours.
Pyrolysis of tyre is done in the absence of oxygen.
Scrubbing of pyrolysis oil, hydrocarbon gases and fuel
gases to prevent pollution.
9. TYRE PYROLYSIS PLANT NEEDS FOLLOWING
MACHINERY & EQUIPMENT
Raw material handing section.
Pyrolysis reactor.
Hydraulic cutter.
Hydraulic auto feeder.
Condensation system.
Scrubbing system.
Hydrocarbon gas cleaning & storage system.
Pyrolysis oil storage system.
Cooling tower.
Control panel and alarm systems.
Equipment line in commercial pyrolysis plants is further modified to
suite customer's requirements.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
REACTOR
Made from heat resistance Plate.
It is of three types
A. Flat model
B. Capsule model
C. Flat and capsule combination.
Reactor is consider as the heart of
this plant.
Raw material feed inside will start
converting to gas at 300-350 degree
Celsius.
Anaerobic heating process takes
place.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
INSULATION TANK
It is also called gas
separator tank because
gas obtained by heating
raw material from reactor
will get separate here.
Hence oil produce will
store in the bottom of tank
and gas will move further
to water coolant pipe.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
WATER SEAL TANK
It is also called the vertical
tank which is jacketed from
all sides and coolant pipe is
connected to this tank.
Gas and oil will come from
the water coolant pipe to
water seal tank and oil will
store to oil tank which is
connected to water seal
tank.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
CARBON HOLDING TANK
Carbon holding tank
which is in water seal
tank in this tank oil and
carbon will mix well a n d
will move to pipe
condenser and car bon
particles will set down.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
GAS TANK
Gas tank is made from 5 mm
MS plate . This excess
hydrocarbon gas which is in gas
tank is very dry and does not
contain any oil particles . Hence
we can either burn it through
auto spark at the end of the
chimney to release in the air or
can be stored in gas balloon in
order to reuse it as agent in the
chamber for heating reactor in
next recycling process.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
UNDERGROUND OIL TANK
Should be 40% oil store
in this tank.
Light gas transfer to gas
tank from this under
ground oil tank.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
WATER COOLANT PIPE
(HORIZONTAL)
It is also called Jacketed pipe.
Here the water gets circulated
inside the pipe that lowers the
temperature of vapors
converting it into oil.
Thus oil and uncondensed
vapors gets separated here
leaving oil at the bottom of the
tank and gas moving further.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
CONDENSING PIPE
This pipe is very useful to increase Yield
Percentage.
It is usually designed in zigzag pattern, so
it creates huge condensing area. Very
easy to maintain.
Condenser is coil type. Total 24 coils are
used in this pipe.
The more the coils faster the cooling
process. Hence more yield percentages
obtained.
Continuous water supply converts
condensed vapor into oil, which is
transferred into oil receiving tank and the
uncondensed gas travels to the next level.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
COOLING TOWER
It has 70 TR capacity.
It is very useful for
cooling of hot vapors to
oil.
It generally has a very
long life.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
SMOKE CHIMNEY (100 FEET)
Smoke chimney is connected
to wet scrubber system.
Black smoke is converted to
white smoke via scrubber
system which will be released
through chimney into air.
It is of 100 FT so that
pollution is prevented into air.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
BLOWER
It helps reducing the processing time
of whole process to maintain number
of batches throughout the month.
It is used to decrease the
temperature of reactor quickly, which
helps increase the number of
batches.
This in total helps increasing the
productivity & With the help of
cooling blower at least 24 batches
can be achieved in a month.
It has 5HP motor which is to take the
hot smoke out of the plant.
10. TYRE PYROLYSIS PLANT & ITS COMPONENTS
WET SCRUBBER SYSTEM
It consist of water
sprinklers inside the pipe.
Polluted smoke coming
from the process is
continuously sprinkled by
water.
Hence carbon gets settle
down at the bottom of the
tank & white smoke will be
released through chimney.
11. TECHNICAL DETAILS OF 12 TON TYRE
PYROLYSIS PLANT
S/
ITEM CONTRACTION DESCRIPTION
N
Main Reactor-12 16 mm BQ Plate Capsule Type (FI-RC- 6.6 Meter(l) x 2.8 Meter(w),
1
ton 12) Plate Thickness-16 mm
Capacity of Cerawool 1260
2 Reactor Cover Insulated with Cerawool Degree Celsius with 25 mm
Two Layer
6” Pipe 24 Nos condenser
Electric Resistance Welded Pipe
3 Pipe Condenser with carbon Holding Tank - 3
(ERW) – MS
Nos (150 Liter capacity
4 Insulation Tank 5 mm MS Plate 800 mm x 1550 mm
500 mm x 1250 mm - 250
5 Heavy Oil Tank 5 mm MS Plate
Liter
1200 mm x 2000 mm With 4”
6 Water Seal Tank 5 mm MS Plate
Water Jacket
7 Gas Tank 5 mm MS Plate 800 mm x 1550 mm
8 Oil Tank 5 mm MS Plate 1470 x 3000 (5.0 KL ) 2 Nos
11. TECHNICAL DETAILS OF 12 TON TYRE
PYROLYSIS PLANT
S/
ITEM CONTRACTION DESCRIPTION
N
Scrubber Reactor Electric Resistance Welded Pipe
10 Top Pipe 12" X 23 Feet
Top Pipe (ERW) – MS
Electric Resistance Welded Pipe
11 Scrubber Fan Pipe 12" X 10 Feet
(ERW) – MS
Scrubber Joint Electric Resistance Welded Pipe
12 12" X 10 Feet
Pipe (ERW) – MS
Scrubber Coolant Electric Resistance Welded Pipe
13 12" X 15 Feet
Pipe (ERW) – MS
Scrubber Tank Electric Resistance Welded Pipe 1000 mm x 2800 mm with
14
(Dust Tank) (ERW) – MS Water Spray Pipe
High Pressure
5 HP 1440 RPM Standard
15 Vacuum Blower 5 mm MS Plate
Electric Motor
(Dust Blower)
Centrifugal 5 HP 1440 RPM Electric
16 5 mm MS Plate
Cooling Blower MOTOR
2 Tons chain block with 10
11. TECHNICAL DETAILS OF 12 TON TYRE
PYROLYSIS PLANT
S/
ITEM CONTRACTION DESCRIPTION
N
5"Gear Box With 5 HP Electric
18 Hoist 5 mm MS Fabricated Motor With Wire Roap 100
Feet(L), 10mm(T)
Total motor Controller, Temp.
Reactor Penal board With Dual Motor Indicator & controller with
19 Penal Board
Arrangement hooter System, Pressure
Indication
5 HP 3 Phase Electric Motor
Submersible
20 Pump Atlas brand for cold water supply in
Water Pump
condenser
3 HP 3 Phase Electric Motor
21 Gear Pump Pump Atlas brand
for oil transfer
3 HP 3 Phase Electric Motor
22 Mud Pump Pump Atlas brand
for scrubber systems
Electric Resistance Welded Pipe
23 Chimney 60 Feet- Chimney
(ERW) – MS
11. TECHNICAL DETAILS OF 12 TON TYRE
PYROLYSIS PLANT
S/
ITEM CONTRACTION DESCRIPTION
N
100x450 mm for Extra Gas
Electric Resistance Welded Pipe
25 Gas Burner Burning Situated at Extra 0.5
(ERW) – MS
HP Blower
Fire Chamber
Electric Resistance Welded Pipe 3 HP 1440 RPM Electric
26 with 3 HP Blower
(ERW) – MS Motor, 100x450 mm
& Gas Burner
27 Cooling Tower Capacity 80 TR 3 HP 2880 RPM Motor
Hardware for reactor pipe
28 Hardware As per annexure I
and pipe fitting
29 Electric Motor Standard make As per annexure II
Price not including in basic
30 Foundation As per drawing
Price
180 Center with 4 Reduction
31 Reactor Gear Box Shricon Brand with Casting Body
Helical Gear Box
12. ASSEMBLY DRAWING FOR FI-RC-5 TPD MODEL
2 VERTICAL + 1 HORIZONTAL CONDENSER
12. ASSEMBLY DRAWING FOR FI-RC-10 TPD
MODEL 2 VERTICAL + 4 HORIZONTAL CONDENSER
12. ASSEMBLY DRAWING FOR FI-RC-12 TPD 10TH
GENERATION MODEL
13. TECHNICAL PARAMETER OF TYRE PYROLYSIS
PLANT
S/
ITEM MODEL MODEL MODEL
N
1 Equipment Type FI - RF-5 FI - RC-10 FI-RC-12
2 Raw Material Nylon / Radial Tyre Nylon / Radial Tyre Nylon / Radial Tyre
3 Structural Form Horizontal rotation Horizontal rotation Horizontal rotation
4 24-Hour Capacity 4.3 ton 8.5 ton 10.5 ton
Oil Yield [40 to 45%
5 1.72 ton 3.8 ton 4.4 ton
oil]
Steel Scrap [15 to
6 0.86 ton 1.7 ton 1.6 ton
20%]
7 Carbon [30 to 35 %] 1.29 ton 2.5 ton 3.6 ton
Normal ( 0.1 To 0.3 Normal ( 0.1 To 0.3 Normal ( 0.1 To 0.3
8 Operating Pressure
Kg) Kg) Kg)
B.Q.Plates SA 516 B.Q.Plates SA 516 B.Q.Plates SA 516
13. TECHNICAL PARAMETER OF TYRE PYROLYSIS
PLANT
S/
ITEM MODEL MODEL MODEL
N
Thickness of
10 12 mm 14 mm 16 mm
Reactor
Rotate Speed of
11 0.3turn/minute 0.3turn/minute 0.3turn/minute
Reactor
12 Total Power 20KW 25KW 33KW
Mode of Water
13 Circular cooling Circular cooling Circular cooling
Cooling
Cooling Area of
14 20 Sq.Meter 51 Sq.Meter 77 Sq.Meter
Condenser
15 Kind of Transmission Dual speed motor Dual speed motor Dual speed motor
16 Noise dB(A) ≤85 ≤85 ≤85
Size of
17 2.2×6.0 Mt. 2.6×6.6 Mt. 2.8 × 6.6 Mt.
Reactor(D×L)
13. TECHNICAL PARAMETER OF TYRE PYROLYSIS
PLANT
S/
ITEM MODEL MODEL MODEL
N
Intermittent
18 Working Form Intermittent operation Intermittent operation
operation
19 Lend Requirement 10,800 Sq Feet. 10,800 Sq Feet. 15,000 Sq Feet
20 Delivery Time 10 Days 10 Days 10 Days
21 Installation Time 15 to 20 Day 15 to 20 Day 15 to 20 Day
22 Training Time 5 Days 5 Days 5 Days
14. TYRE PYROLYSIS PLANT – MODEL LIST
SIZE IN
S/N MODEL MODEL NAME
METER
FI-RC-5 Ton (2 Vertical Condenser + 1 Horizontal
1 5 Tons 2.2 x 6.0
Condenser)
7.5 FI-RC-7.5 Ton ( 3 Vertical Condenser-1 Horizontal
2 2.2 x 7.5
Tons Condenser)
FI-RF-10 Tons 4th Generation ( 4 + 1 Vertical
3 10 Tons 2.6 x 6.6
Condenser)
4 10 Tons 2.6 x 6.6 FI-RC-10 Tons 10th Generation Model
5 10 Tons 2.6 x 6.6 FI-RFC-10 Tons 10th Generation Model
6 12 Tons 2.8 x 6.6 FI-RC-12 Tons 10th Generation Model
7 12 Tons 2.8 x 7.5 FI-RFC-12 Tons 10th Generation Model
8 15 Tons 3.0 x 7.1 FI-RF-15 Tons Pipe - (Pipe Condenser - 6" - 32 pipe)
14. TYRE PYROLYSIS PLANT – MODEL LIST
ABBREVIATION
FI FAB INDIA
RF REACTOR FLAT TYPE
RC REACTOR CAPSULE TYPE
RFC REACTOR FLAT CAPSULE TYPE
AUXILLIARY EQUIPMENTS
Tyre Side Wall Cutter
Hydraulic Tyre Cutter
Tyre Cutting Equipment Tyre Ring Cutter
Tyre Steel Removing Machine
Tyre Block Cutting Machine
14. TYRE PYROLYSIS PLANT – MODEL LIST
AUXILLIARY EQUIPMENTS
Tyre Side Wall Cutter
Hydraulic Tyre Cutter
Tyre Cutting Equipment Tyre Ring Cutter
Tyre Steel Removing Machine
Tyre Block Cutting Machine
Belt Conveyor For Cutting Tyre
Tyre Feeding Equipment
Hydraulic Auto Feeder Machine
14. TYRE PYROLYSIS PLANT – MODEL LIST
AUXILLIARY EQUIPMENTS
Carbon Screw 18 Feet
Carbon Handling Equipment Carbon Vacuum System
Carbon Briquetting Machine
Oil water Separater system with waste water
Evaporating System
LDO Bunner system for heating chamber
Pollution Regulating Equipment
Hydrocarbon Gas storage device (balloon)
Industrial Chimney 100 Feet
Nitrogen Punching Device
15. EVALUTION OF EXPENSES AND GROSS PROFIT
S/N CONTINGENT EXPENSES PER MONTH AMOUNT IN RS
1 Postage and Stationery 6,000.00
2 Telephone 5,000.00
3 Traveling and Freight 20,000.00
4 Consumables 34,000.00
5 Repair and Renewals 20,000.00
6 Insurance Fire and Employee 10,000.00
7 Rent Nil
TOTAL AMOUNT 1 95,000.00
15. EVALUTION OF EXPENSES AND GROSS PROFIT
UTILITES
S/
EXPENSES PER SALARY IN RS NOS AMOUNT IN RS
N
MONTH
1 Production Manager 25,000 01 25,000.00
Maintenance
2 18,000 01 18,000.00
Engineer
3 Purchased Manager 25,000 01 25,000.00
4 Semi-skilled Workers 15,000 06 90,000.00
5 Watchman 10,000 01 10,000.00
6 Additional Perquisites @ 20% 33,600.00
7 Waste Tyre 10,500 Kg Per Day x 22Days x Rs 9 Per Kg 20,79,000.00
8 Coal/Wood 1800 Kg Per Day x 22Days x Rs 4/Kg 1,58,400.00
9 Power 45 HP x 0.8 x 24 Hours x 22 Days x Rs 6 40,000.00
10 Water 8,000.00
TOTAL AMOUNT 2 24,87,000.00
TOTAL RECURRING EXPENDITURE (PER MONTH) RS TOTAL
15. EVALUTION OF EXPENSES AND GROSS PROFIT
S/N TURNOVER PER MONTH PRESENTED PER MONTH
By Selling Oil 4410 Ltrs*22 days*Rs
1 42 to 45% 31,04,640.00
32/Ltr
By Selling Steel Scrap
2 15 to 20% 2,77,200.00
1575kg*22days*Rs8/kg
By Selling Carbon 3465Kg *22days*Rs
3 30 to 35% 1,14,345.00
1.5 /kg
4 Gas Around Recycling 5 to 10% Nil
5 Turnover Per Monthly 34,96,185.00
6 Total Recurring Expenditure (Per Monthly) Rs 25,82,000.00
7 Monthly Gross Profit 9,14,185.00
GROSS ANNUALLY PROFIT 1,09,70,220.00
15. EVALUTION OF EXPENSES AND GROSS PROFIT
TERMS & APPROXIMATE
S/N DETAILS
CONDITIONS PRICE
1 12 Tons Machine Cost Without Tax 52,00,000.00
2 Transportation Cost Trailer/ Trucks 1,50,000.00
3 Shed Fabrication Works [Open Shed] 50 Feet x 100 Feet 5,00,000.00
4 Oil Storage Tank 25000 Litre 1,50,000.00
5 Foundation Cost Only Machine As Per Drawing 3,50,000.00
6 D.G. Generation Set [40 KW] Standard 3,50,000.00
7 Site Office [Medium] 10 x 10 Feet x 2 Room 3,25,000.00
8 Pollution Certificate 50,000.00
Electric Connection/Cable/Wiring
9 25,000.00
Connection Charge
10 Other Expenses 1,00,000.00
TOTAL INVESTMENT OF 12 TONS PLANT (WITHOUT LAND
72,00,000.00
& RAW MATERIAL INVESTMENT WORKING CAPITAL)
Thank You !
