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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).
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.
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
Pyrolisis
Distillery
Steel Scrap
Diesel
Gasoline
Fuel Oil
Rodrigo Triana
STEEL SCRAP 15 %
Distillation
Fine Carbon Commercial Carbon Carbon black Coarse Pyrolityc carbon black
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
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
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