Scrap Tyres to oil production - A project profile by SMB Environmental Projects Pvt Ltd

SMB ENVIRONMENTAL PROJECTS PVT. LTD.Cell No : +91 98602 40852, 96650 40852, 96650 40852, 96855 75970

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PROJECT REPORT

(Waste Recycling Renewable Energy Project)

REUSE - REDUCE – RECYCLE

113 / 14, Seva Sadan Building, CA Road, NAGPUR – 440 018,

Phone : +91 7263 – 259052, Mobile : +91 9860240852Email: [email protected] [email protected]

Web : http://www.smb-project-consultants.com/

FULLY INTEGRATED 10 MTPD TYRE PYROLYSIS PROJECT FOR CONVERSION OF SCRAP TYRES INTO

HIGH GRADE FURNACE OIL & LIGHT SPEED DIESEL OIL

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I. INTRODUCTION

The present Project is centered on a “Breakthrough” Technology to turn a

potentially hazardous waste product, namely, waste rubber and scrap tyres,

into valuable INDUSTRIAL FUEL, called Pyro Diesel / Furnace Oil, which is a

high-grade substitute for Furnace Oil and Light Diesel Oil (LDO).

This is one of the first Integrated Plant Configurations with an Auto-feeder

and a Semi-continuous Pyrolysis Reactor; Carbon Black Fine Milling Station

and an Ash Removal System for the Carbon Black. This cutting edge Plant

Machinery Line is available at a most reasonable price. Problems associated

with uncontrolled or illegal waste rubber dumping and scrap tyre disposal

and burning are now a thing of the past!

1.1 Raw Material Availability:

The scrap tyre generation in industrialized countries is approximately, one

Passenger-car Tyre Equivalent (PTE), at the rate of 20 lbs., or 9 kg per person

per year. It is estimated that 2 to 3 billion scrap tyres are stockpiled in illegal

or abandoned piles throughout North America, Europe, and Middle East! In

India, with the exploding Automobile industry dimensions, it is safe to

assume scrap tyre piles are growing to the extent of Lakhs of tons per

annum. Scrap tyres are available in abundance in the Middle Eastern

countries, and their import as cut pieces is freely allowed by the Govt. of

India for certified industrial end users.












It is estimated that annually, about a Million Tons ( about 10 Lakh Tons) of

scrap tyres are available in India, and this figure is increasing in leaps and

bounds as the vehicle numbers in the passenger, commercial and industrial

sectors in India too are catching up to the Western levels! Earlier there was

one car for every 500 households (upper Middle Class). Now, for every

(above lower Middle Class) household, there is a vehicle of one description or

the other generating scrap tyre waste. Further, the famous India “Tyre

Retreading” Industry is virtually closed now, since the retreading is out of the

vehicle user’s ethos these days. Thousands of tons of scrap tyres are

available to be organized through a network of scrap tyre pickers and scrap

dealers in India at economically viable rates.

Literally mountains of scrap tyres are lying around in

USA & Europe & ME countries!












1.2 The scrap tyre heap is a mosquito breeding ground:

The second problem often caused by illegal tyre piles involves disease

carrying mosquitoes, which tend to breed in great numbers in the

protected water puddles of the tyres. Especially in areas with warmer

climates mosquito-borne diseases like encephalitis and dengue fever have

been reported around large tyre piles

………General Info continues ……

II. FULLY INTEGRATED PYROLYSIS TECHNOLOGY:

Pyrolysis of waste tyre rubber consists of controlled-temperature catalytic de-

polymerization, in the absence of oxygen, that is, without smoke and

burning, to obtain a valuable fuel oil called Pyro Diesel Oil (PDO). The rubber

char remaining as a residual byproduct is called carbon black, which is also a

very useful industrial raw material in great demand, provided its quality

parameters are properly upgraded, which is done in our technology.

Pyrolysis process is the thermal decomposition of organic materials in an

oxygen-free environment and is an endothermic reaction. It requires an input

of heat energy, pressure and pre-determined temperature depending on the 4

13 / 14, Seva Sadan Building, CA Road, NAGPUR – 440 018,Phone : +91 7263 – 259052, Mobile : +91 9860240852

Email: [email protected] [email protected] : http://www.smb-project-consultants.com/









organic material to be pyrolized. Pyrolysis process has phases and in each

phase different decompositions originate; therefore, different products

(steam, gas, oil, etc.) are obtained. Phases of the process are determined by

the process temperature; pressure, duration, and the variety of organic

materials to be processed (scrap tyre, plastic bottles, medical waste, etc.).

2.1 Saleient Features of the process and operations:

........Salient Features and other details continues......

2.2.1 Quality of Furnace Oil produced from the pyrolysis

process:












CHARACTERISTICS OF OIL PRODUCED

Properties Value

Density, gm / cc 0.9612

Flash Point, deg C – PMCC, min 70

Pour Point. Deg C, max +3

Kin Viscosity CS @ 40 deg. Max 36

Sulfur, Total. % by weight, Max 1.17

Sediment, % by weight, max 0.02

Gross Cal Value, K Cal / Kg 10101

Ash content, % by weight, max 0.01

Water content, % by Vol, Max < 0.05

The furnace oil meets all the specifications as per ISI / BS and is a valuable

fuel readily saleable in the industrial market at prices ranging between

Rs. 45,000 to 50,000 per tonne.

2.2.2 Quality of Carbon Black produced from Pyro process:












Properties Value

Absorption, cc / 100 gms 78

Surface Area, M2 / gm 68

PH value 9

Heating Loss, % max 1.5

Ash Content, % max 10

Avg Particle size, micron 200 – 400 mesh

This is also a valuable industrial intermediate product, used in the following

industries:

Cable Jacketing

Conveyor & Career bands












Black Nylon bags

Hose and Doormats

Rubber Additive

Automobile Spare parts

Black colorant in rubber

Plastic pipes

Fire Fighting

……..Process details and the facilities continue…..

Photographs of a few important equipment of the system:

REACTOR UNIT












OIL CONDENSATION & SEPARATION












CARBON BLACK EXTRACTION & CONVEYOR SYSTEM









BAR CHART FOR THE PDO PROJECT IMPLEMENTATION

Month 1 2 3 4 5 6 7# Activity

1 Preliminary activities

a. Company Formation

b. Signing of plant machinery supply contract

c. Preparation of DPR

d. Submission of loan documentation to Banks

2 Land purchase or lease

3 Land development & infrastructure (power & water)

4 Project appraisal & loan sanction

5 Building construction

6 Placing of orders for aux.equipment & fabrication work

7 Receiving of Plant machinery at site

8 Recruitment of project personnel

9 Erection & commissioning

10 Commercial Production

OR GANI ZAT I ON CHAR T

M ANAGI NG DI R ECTOR

P LANT M ANAGER /ENGI NEER

SHI FT SUP ER VI SOR S

SKILLED ELECTRICIANS

SK I LLED F I TTER S

SEM I -SK I LLED WOR K ER S

WATCH & WAR D




III. PROJECT IMPLEMENTATION SCHEDULE:

BAR CHART –WASTE TYRE - OIL PROJECT IMPLEMENTATION

IV. MANPOWER & ORGANIZATION CHART:












It is estimated that a total of 10 persons are required to run this plant based on

2 shift semi-continuous operations. Also an experienced gang of operating

personnel is being preferred nowadays, which is taking up the operating

contract @ Rs. 7 to 8,000 per batch and can give as many as 25 batches in a

month. So the manpower cost excluding the company supervisor and

accountant shall be appx. Rs. 24 Lakh per year. Add Rs. 6 Lakhs for company

manpower. So the yearly expenses will be Rs. 30 lakhs.

V. Environmental & Socio-Economic Benefits:

5.1 Prevention of Major Environmental Pollution

The details will be covered in a DPR.

5.2 Advantages of this project for the environment:

The present project has a major advantage above any other technology in

protecting the environment as described herein.

5.2.1 No Exhaust gas is let out to pollute the air

Full combustion in water seal and gas burner with safety devices, the pollution

to exhaust gas is eliminated and a large amount of fuel shall be saved.












The gases shall be either stored for further use in process or shall be burnt in a

incinerator cum scrubber, pre treated in wet scrubber before discharging to

atmosphere.

5.2.2 No Waste liquid effluent is let out to pollute water & soil

Faint acidic waste water will be produced in the course of treatment of oil

products (about 50 kg of waste water per ton of oil). This water is neutralized by

passing through a wet scrubber and evaporated in a specially designed

evaporatoer cum gas burner system.

5.2.3 No Waste solids are dumped as landfill

The residue left from catalysis and split of waste tires is only carbon black,

which is a useful industrial raw material and saleable product.

5.3 Conservation of Valuable Foreign Exchange

Light Speed Diesel Oil ( LDO ) and Industrial Furnace Oil (IFO) is mostly an

imported commodity or imported crude based derivative.

Hence, the production of PDO will save foreign exchange outflow.

5.5 Rural Development Stimulator

Recovered LDO & IFO being suitable fuel oils for rural pump sets and gen-sets, will help in mitigation of the sufferings of the farmers, who suffer heavy power cuts throughout the year.

5.4 Special Features of this project vis a vis Environmental Protection: ………….Special feature continues…….

VI. PROJECT PROFIABILITY & FINANCIAL ASPECTS

6.1 Installed capacity of the Pyrolysis Plant: 10 MTPD












( 8 Tonnes per Batch )

6.2 Product Yield

a. Light Diesel Oil / Furnace Oil @ 40 % of 2400 Tonnes of tyres

(Sp Gravoty of Oil is taken as 0.96) : 960 KL p.a.

b. Carbon black- Hi-Grade: @ 30% of feed : 720 MT p. a.

(slightly variable, subject to fraction of carbon black purified)

c. Steel scrap @ 12 % : 288 MT p. a.

(variable, subject to fraction of radial tyres in the

scrap)

6.3 Product selling prices:

a. Industrial Furnace oil: Rs. 40 per liter

b. Carbon black: Rs. 5 per kg

(could be much higher, if pelletized as fuel )

c. Steel scrap: Rs. 15 per kg (variable)

d. Raw material cost: Rs. 10,000 per MT

6.4. Yearly revenues : 960 x 40,000 + 720 x 5000 +

288 x 15000

= Rs. 4,63,20,000 …… A

6.5. Estimated Expenditure per year:












6.5.1 : Cost of Power: 40 HP & utilites like fuel etc. = Rs. 15,00,000

6.5.2 : Cost of Manpower = Rs. 30,00,000

6.5.3 : Cost of Raw Materials = Rs. 2,40,00,000

6.5.4 Rent for the land and shed @ Rs. 25,000 per month = Rs. 3,00,000

6.5.5 Gen Expenses like phone, courier, travelling,

postage, pollution control testing etc. = Rs. 6,00,000

Total Expenditure ( Operating Expenses) = Rs. 2,94,00,000 ..B

6.6 Estimated Profit Margin per year

( before taxes, duties & depreciation ) = A – B

Rs. 1.42 crores

6.6 COST OF PROJECT:

6.6.1: Capital Cost ( Will Work out in the DPR ) as it depends on the

facilities to be included in the project.

- Cost of Land ( Taken on a Lease) = Nil

- Cost of Plant & Machineries = Rs. ______ lakhs

- Cost for Pre-project activities = Rs. ______ Lakhs

-----------------------------------------

Total Capital Cost =

--------------------------------------------6.6.2:

Working Capital:












- Investment in 7 days raw materials: 7 x 8 x 10,000 = 5,60,000

- Salary & Wages for 2 months: 30 x 2 / 12 = 5,00,000

- Fuel, utilities & other running expenses – 1 month = 24/12 = 2,00,000

Total Working Capital requirement = Rs. 12,60,000

7.0 Marketing Potential:

Furnace Oil is in short supply. It is a commodity of daily consumption for a

large number of industries and hence, very easy to sell. Moreover, it is a

“cash & carry” business.

Hi-grade refined Carbon black produced in our plant fetches good price

even without refining and also easy to sell at factory doorstep.









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Scrap Tyres to oil production - A project profile by SMB Environmental Projects Pvt Ltd