Manufacturer Of Waste Tyre Recycling Plant

Project Report

REUSE
REDUCE
RECYCLE

Welcome to FAB INDIA

Fab India Is a Pioneer in the Field Of Designing, Developing and Quality Manufacturing with
more than 20 years experience situated at Ahmedabad, Gujarat. Fab India is professional and
high-tech companies to manufacture waste tyre recycling plant with a wide range (5 ton, 7.5
ton, 10 ton and 12 ton), good quality, reasonable prices, all the safety precautions and stylish
designs, This ISO 9001:2000 company has achieved this stature with over a decade of total
commitment and continuous improvement and introduction of new products. Fab India follows
the globally approved QMS (Quality Management System).

Company Profile

Established in the year 1991, we fab India is a Dominant firm involved in manufacturing,
supplying and installation of Pyrolysis Equipment and Waste Tyre Recycling Plant. We also have
our 3-manufacturing unit, which has been operating since 1993 regarding pharmaceutical
machinery , chemicals plant, minerals plant, food processing plant, textile plant etc. Moreover,
This ISO 9001:2000 Company has introduced the most viable process for recycling plastic
scrap and used tyre into fuel oil, carbon black, steel wire and hydrocarbon gas. Our Ecofriendly technology is known for transforming over 10 billion squirrel away tyres around the
world into energy.
~ to 15/
At our ultra modern infrastructure, we have been manufacturing a premium range (=13
month) of recycling equipment. We are known for providing complete recycling solutions to
clients with proven technologies. Along with this, we possess vast experience in Designing,
Developing and Quality of equipment, along with technical analysis. Our pyrolysis plants are
constructed & examine under the Diligence of our qualified experts, who ensure to dispatch only
a qualitative range to customers. We also provide customized solutions to clients as per their
specifications.
Under the constant support of our Director, Mr. Suresh Patel'. We have been growing in this
industry. His tremendous knowledge, leadership, expertise skills and experience has enabled us
to export our products to all over India.

Fab Indias workshop

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.
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 molecules.
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.
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".

 Variety of polymer waste material is suitable as a raw material.

Given below is the list of suitable raw materials for pyrolysis:

Waste tyres
Rubber or rubber parts from vehicles
Electronic scrap
Mixed (HDPE, LDPE, PE, PP, Nylon, Teflon, PS,ABS,FRP etc)
Multi layered
Plastic disposable bottle

The choice of feedstock and process (mainly operating temperature) can affect the value of
the finished products.
Input-output ratio of waste tyre
Type of Material

Total Quantity

Nylon scrap tyres

1000 kgs

-550 to 600 liter of Pyrolysis oil

-50 to 80 kg of Hydrocarbon Gas
-300 to 350 kg of Carbon Black

1000 kgs

-400 to 450 of Pyrolysis oil

-50 to 80 kg of Hydrocarbon Gas
-300 to 350 kg of Carbon Black
-150 to 200 kgs of Mild steel tyre scrap

Radial scrap tyres

Finish quantity

Yield of pyrolysis process:

H Pyrolysis oil (Fuel oil 40 to 45%)
The essential product of tyre pyrolysis process is pyrolysis oil referred as fuel oil (40 to
45 % of total quantity feed) which is used as a fuel component for heating in fire chamber.
Pyrolysis oil has flash Point between 60 to 93.3 C.
Purest quality of pyrolysis oil comparable to industrial diesel: selling price comparable to
industrial diesel LDO( light diesel oil)
H Carbon Black(30 to 35%)
The vital product of pyrolysis plant is carbon black referred as "charcoal"(30 to 35% of
total quantity feed).carbon black has Industrial and commercial use.
H Steel wire(15 to 20%)
For instance, whole tyres contain fibers and steel. Shredded tyres have most of the steel and
sometimes most of the fiber removed.
The steel wire(15 to 20%) can be removed from the carbon black with magnets for recycling
after pyrolysis process & sold to the steel dealer
H Hydrocarbon Gas(5 to 8%)
The 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 (5 to 8% of total
quantity feed) which can be burned as fuel.
5

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:

Pyrolysis oil(Fuel oil)

Carbon black
Steel wire
Hydrocarbon gas

H Advantages of pyrolysis plants

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.
H Benefits of 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.
H

Basic function of pyrolysis plant is to achieve following process conditions:

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.

H 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.
6

Pyrolysis oil storage system.

Cooling tower.
Control panel and alarm systems.
Equipment line in commercial pyrolysis
plants is further modified to suite
customers requirements.

Shell Plate

(B.Q. Plate SA 516 Gr.70)

Test Report

Flowchart for pyrolysis process

Waste tyre (Nylon/Radial tyre)

Pyrolysis process
Pyrolysis plant

Pyrosis oil
(Fuel oil-LDO)

Pyrolysis Oil
Storage System

Deliver to
refinery unit

Carbon black
(charcoal) with
small particle of
steel wire

Carbon black

Storage

Pulverizer
system

Magnate & Sleeve

Collect

Carbon coal Plant

Bracketing Machine

Sale to market

Steel wire

Storage

Compressed

Transfer to
scrap dealer

Hydrocarbon gas

Recycle burning
Unit

Scrubber Unit

Chimney

Technical detail of 12 ton PYROLYSIS PLANT

16

Sr No

Item

Contraction

Description

Main Reactor-12 ton

16 MM BQ Plate Capsule 6.6 Meter(l) x 2.8 Meter(w),Plate

Type(FIRC-12)
Thickness-16 MM ,

Pipe condenser

5 MM MS Plate OR C
Class Pipe -5MM MS

Pipe 24 Nos , diameter-6 inch

Insulation tank

5 MM MS Plate

700 MM x 1550 MM ,Cera

wool(1260 C) insulation covered with
aluminum sheet

Water seal tank

5 MM MS Plate

1000 MM x 1800 MM

Gas tank

5 MM MS Plate

800 MM x 1550 MM

Oil Tank

5 MM MS Plate

1470 x 3000 (5.0 KL ) 2 Nos.

Water coolant pipe

C Class Pipe -5 MM MS
Pipe

(15'X8" & 12'X16" ) [ 15 Feet ] ,

jacketed pipe

Scrubeer Reactors

C Class Pipe -5MM MS

Top Pipe 12" X 10 Feet

Scrubber Fan Pipe

C Class Pipe -5MM MS

12" X 10 Feet

10

Scrubber Coolent
Pipe

C Class Pipe -5MM MS

12" X 15 Feet

11

Scrubber Tank

5 MM MS Plate

1000 MM x 2800 MM with coolant

pipe

12

Dust Blower

5 MM MS Plate

5 HP Blower with Motor

13

Cooling blower

5 MM MS Plate

5 HP 1440 RPM ABB MOTOR

14

Hoist

5MM MS Fabricated

5"Gear Box With 5 HP ABB Motor

With Wire Rop 80 Feet(L), 10MM(T)

15

Chain block

2 Tons Chain block

2 Tons chain block with 10 Feet chain

for reactor door

16

Penal board

Reactor Penal board with

7.5 HP Motor

Total motor Controller, temp indicator

and controller with hooter penal
board

17

Submersible Water
pump

Pump Atlas brand

5 HP 3 Phase Electric Motor for cold

water supply in condenser

18

Gear pump

Pump Atlas brand

3 HP 3 Phase ABB Motor for oil

transfer

Technical detail of 12 ton PYROLYSIS PLANT

Sr No

Item

Contraction

Description

19

Mud pump

Pump Atlas brand

3 HP 3 Phase ABB Motor for scrubber

systems

20

Chimney

C Class Pipe -5MM 12"

MS

20 Feet-2 Nos for chimney

21

Gas Blower

3 Nos Gas blower 0.5 HP

0.5 Hp Motor 3 Phase for fire

chamber

22

gas burner

C Class Pipe -5MM MS

100x450 MM

23

Cooling tower

Capacity 80 TR

3 HP 2880 RPM Motor

24

Hardware

As per annexure I

Hardware for reactor pipe and pipe

fitting

25

Reactor cover

Reactor cover insulation

With cerawool 1260 Temp 25 MM

Two layer

26

Electric Motor

Standard make

As per annexure II

27

Foundation

28

Reactor Gear box

Shricon Brand

180 Center 10 HP Helical Gear

29

Fire Brick &

Castable cement

500 Nos Fire Brick

and castable cement 4+4 bags

For fire system

30

Hydraulic
Auto feeder
[ Extra Price ]

5 MM Plate and 100 MM 5 HP Hydraulic Auto Feeder, works

Channel
with 40 tons hydraulic pressure

31

Hydraulic cutter
[ Extra Price ]

16MM MS PLATE

5 HP Hydraulic Auto Feeder, works

with 40 tons hydraulic pressure

32

Material handing
screw for carbon

8"PIPE COVERD with

12"PIPE(5MM) with
cooling system

3 Hp motor WITH 4"GEAR,18 feet

long

As per drawing

Price not including in basic Price

17

14
1

4
6

4
6

4
6

5
1

4
6

FI - RC - 12 TPD Pipe
Condenser Model

70 TR

Technical Parameter
MINIMUM LAND REQUIREMENT FOR PLANT : 50' X 120'(FEET)
TOTAL LAND REQUIREMENT FOR PLANT : 90' x 120'(FEET)
Foundation drawing will be send by us
S.N

Items

Model

Model

Model

Equipment type

FI - RF-5

FI - RC-10

FI-RC-12

Raw material

Nylon / Radial Tyre Nylon / Radial Tyre Nylon / Radial Tyre

Structural form

Horizontal rotation

Horizontal rotation

Horizontal rotation

24-hour Capacity

4.3 ton

8.5 ton

10.5 ton

Oil yield [40 to 45 % oil]

1.72 ton

3.8 ton

4.7 ton

Steel Scrap [15 to 20 %]

0.86 ton

1.7 ton

2.1 ton

Carbon [30 to 35 %]

1.29 ton

2.5 ton

3.1 ton

Operating pressure

Normal ( 0.3 To
0.5 Kg)

Normal ( 0.3 To
0.5 Kg)

Normal ( 0.3 To
0.5 Kg)

Material of Reactor

B.Q.Plates SA 516
Gr.70

B.Q.Plate SA 516
Gr.70

B.Q.Plate SA 516
Gr.70

10

Thickness of Reactor

12 mm

14 mm

16 mm

11

Rotate speed of Reactor

0.4turn/minute

0.4turn/minute

0.4turn/minute

12

Total power

20KW

25KW

33KW

13

Mode of Water cooling

Circular cooling

Circular cooling

Circular cooling

14

Cooling area of
condenser

18 Sq.Meter

60 Sq.Meter

70 Sq.Meter

15

Kind of transmission

VFD drive

VFD drive

VFD drive

16

Noise dB(A)

85

85

85

17

Size of Reactor(DL)

2.26.0 Mt.

2.66.6 Mt.

2.8 6.6 Mt.

18

Working form

Intermittent
operation

Intermittent
operation

Intermittent
operation

19

Lend requirement

10,800 Sq Feet.

10,800 SqFeet.

10,800 SqFeet.

20

Delivery time

within 2 weeks

within 2 weeks

within 2 weeks

21

Installation Time

10 to 15 Day

10 to 15 Day

10 to 15 Day

15

Model and Price list

Sr.
No.

Model
(Ton wise)

Capacity
Load
Shell
in kilo
in
diameter
liter
ton
(MM)

Shell
Length
(MM)

Plate
Price
thickness
INR
(MM)
(Lac)

Condenser
Nos

Coolant
area
Sq. Mtr

FI-RF-5 T

24 KL 4.5 2200

6000

12

32

1+1

20

FI-RF-7.5 T

30 KL 6.9

2200

7500

14

35

25

FI-RF-10 T

37 KL

2600

6600

16

39

4+1

31

FI-RC-10 T
4 Pipe condenser 37 KL
(Economy Model)

2600

6600

14

42

24 Nos Pipe
Condenser In series

51

FI-RC-10 T

35 KL

2600

6600

16

44

24 Nos Pipe
Condenser In series

51

FI-RC-10 T
5th Genration

37 KL

2600

6600

14

45

2 horizontal,
2-vertical condenser

39

FI-RC-10 T
7th Genration

37 KL

2600

6600

16

48

4 horizontal, 2vertical condenser

46

FI-RC- 12 T

43 KL

11

2800

6600

16

52

24 Nos Pipe 6"

Condenser In series

77
[Pipe]

FI-RF- 15 T

54 KL

13

2800

7100

18

57

32 Nos Pipe 6"

Condenser In series

102
[Pipe]

Installation charge included

Extra Tax -2 % CST Against "C" Form, Transportation Extra
Extra Accessories

18

Hydraulic Auto feeder

Rs 3,10,000

Hydraulic cutter

Rs 3,25,000

Material handing screw

Rs 1,26,000

Chimney Cost Extra 100 feet

Rs 2,20,000

Cable and wire charge not including

in our price

Extra

Payment Terms and Condition

Terms & Condition: Payment
30 % Advance & 70 % Against Delivery

H Evaluation of Expenses and gross profit

S.N

Other Contingent Expenses (per month)

Amount (Rs.)

Postage and Stationery

2,000.00

Telephone

5,000.00

Travelling and freight

15,000.00

Consumables

10,000.00

Repair and Renewals

10,000.00

Insurance fire and Employee

10,000.00

Rent

NIL
Total Amount 1

Total

52,000.00

Utilities (per month)

S.N

Personnel

Salary (Rs.)

Nos.

Amount (Rs.)

Production Manager

25000

25,000.00

Maintenance engineer

15000

15,000.00

Semi-skilled workers

8000

48,000.00

Watchman

8000

8,000.00

Additional perquisites @ 20%

Waste Tyre 11000 kg. per day x 22days x Rs 11per Kg

Coal/wood 2000 kg. per day x 22days x Rs 6/kg

Power 45HP x 0.75 x 24hours x 22 days x Rs 6

Water

11,000.00
26,62,000.00
2,37,600.00
46,000.00
7000.00

Total Amount 2

Total Amount

Total Recurring Expenditure (per month) Rs. Total Amount 1 + Amount 2

Turnover per Monthly

Presented

30,59,600.00
31,11,600.00
Per Month

By selling Oil 4730 Ltrs*22 days*Rs32/Ltr.

42% to 45%

33,29,920.00

By selling steel scrap 2200kg*22days*Rs12/kg

15 %to 20%

5,80,800.00

By selling Carbon 3190Kg *25days*Rs 1.5 /kg

30%to 35%

1,05,270.00

Gas Around Recycling

5% to 10%

Nil

Turnover per Monthly

40,15,990.00

Total Recurring Expenditure (per Monthly) Rs.

31,11,600.00

Profit Gross Per Monthly

Monthly Profit

9,04,390.00

Gross Annually Profit 1,08,52,680.00

19

12 Tons Pyrolysis Plant Total Investment in One Plant

S.N

[without land]

Approximate
Price

Details

12 Tons Machine Cost

Without tax

52,00,000-00*

Transportation cost

Trailer/ trucks

1,50,000-00

Shed fabrication works [open shed]

50 Feet x 100 Feet

5,00,000-00

Oil Storage Tank 25000 Ltr.

Foundation cost only Machine

As per dwg

3,50,000-00

D.G. Generation set [ 40 KW]

Standard

3,50,000-00

Site Office [ medium ]

10 x 10 Feet x 2
Room

3,25,000-00

Pollution certificate

50,000-00

Electric Connection/Cable/Wiring Connection

charge

25,000-00

1,50,000-00

10 Other Expenses

1,00,000-00

11 Land Investment

xxxxxxxxxx

12 Raw Material Expenses

xxxxxxxxxx

Total Investment of 12 Tons Plant

72,00,000.00

"Your Challenge is our Progress"

Works: Plot No.3/4, Khodiyar Estate, Inside Shakriba Estate, Phase IV,
Vatva G.I.D.C, Ahmedabad-382 445.
Soham Patel: +91 97250 12741, Pratul Patel: +91 97250 12747
Other Contacts :+91 97250 12744 /+91 97250 12746.
Office No : +91 8980014620/21. Tel No : +91 79 40301472.
Email Id: info@fabindia.me, info@wastetyreplant.com, fabindia2@gmail.com
Skype ID: FABINDIA3133,
Web Site: www.wastetyreplant.com