Waste Tyre Recycling Plant

(Solving the problem of waste tyres)

Project profile by:

Bioenergy Resources
Pyrolysis Plant

Pyrolysis plant is renewable energy generation system. Pyrolysis plants

are designed to generate quality fuel from polymer waste. Pyrolysis is
the decomposition of organic compounds under oxygen free
(anaerobic) atmosphere. Pyrolysis is the thermal degradation of waste
in an oxygen starved environment in which
gasification takes places.It is an endothermic reaction which requires an
input of energy that is typically applied indirectly
through the wall of the reactor. Pyrolysis is the chemical decomposition
of organic materials by heating in the absence of oxygen
or any other reagents, except possibly steam.

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 waste tyres are mainly composed of
long chain of C-H molecules. 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 recirculated through
process. When performed well a tyre pyrolysis process is a very
clean operation and has nearly no emissions or waste.
Pyrolysis system or pyrolysis plant is an industry for conversion of
waste and tyre into usable products like:

1. FUEL OIL/PYROLYSIS OIL (35% to 40%) 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 35% to
40% of the amount of recycled scrap tyres, which will be carried
with licensed tanker trucks.
2. CARBON BLACK (35% to 45%) Carbon Black is the main product
recycled by Pyrolysis technology. The amount of recycled carbon
black is 35% to 45% 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.
▪ Electric cable jacketing
▪ Conveyor band
▪ Carrier Bands
▪ Hose and doormat
▪ Black nylon bag, Plastic pipes
▪ Rubber additive
▪ Automotive spare parts
▪ Black colorant in rubber materials

3. STEEL WIRE (10% to 15%) 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 detached after the Pyrolysis
recycling process is completed. Valuable steel wires are pressed
and sold to steel and scrap dealers.
4. GAS (5% to 8%) Non-Condensable gases arise during the
pyrolysis process. There are some advantages such as…..
• It has higher calorific value as compared to natural gas.
• 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 5% to 8% of the
total amount of recycled tyres and considering the 8 ton scrap
tyre/batch recycling capacity, the facility generates 400 - 640
m³/batch gas.

Utilisation of Waste Generated in Process

1. Moisture content in the Pyrolysis oil which is around 5%
(150 lts approx per batch) is utilized as fuel in the process
in place of fire wood , with the help of air compressor
and fuel burner equipment. There is no external water
requirement for the process such as ground water etc.
The water generated during the process is also utilized
which results in zero water contamination.

2. The Hydrocarbon gas generated during the process is also

used as fuel in the process and it results in saving the
firewood required to generate heat. No Hydrocarbon gas
is released in the environment as it all gets consumed.
PROCESS FLOWCHART
Basic function of pyrolysis plant is to achieve following
process conditions:
• Operating temperature of Reactor is between 300 to 350 degree.
• Duration period of pyrolysis batch is between 10 to 12 hours.
• Pyrolysis of tyre is done in the absenceof oxygen.
• Scrubbing of pyrolysis oil, hydrocarbon gases and fuel gases to
prevent pollution.

USES OF FUEL OIL/PYROLYSIS OIL

The fuel is an excellent fuel and can be used for
• Diesel electrical generators
• Diesel burners
• Industrial Boilers
• Hot air generators
• Hot water generators
• Diesel pumps
• Heavy Machinery in Construction Companies