5th generation waste tyre recycling...

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5th GENERATION “WASTE TYRE RECYCLING PLANT”

Registered Office: 520-527 Poddar Arcade, Khand Bazaar, Varachha Road, Surat 395 006 (Guj) India

Contact Numbers: +91 261 2554150/51/52 Fax: +91 261 2554149


5TH GENERATION 10 TON PLANT LAYOUT.


10 TON PLANT PROJECT REPORT

Company Profile: Anjali Exim with its unique renewable technology has come up with a concept of setting new standard in renewable energy that includes using of waste tyres as a raw material and producing green fuel oil, carbon black, steel and gas. With global warming and utilization of rubber, it has now become necessary to recycle the waste and convert it in fuel oil in such a way that it is environment friendly. This is a unique technology and can be change energy market scenario in a big way. Anjali Exim has a team of experienced and expert recycling, consulting and marketing Professionals that work hard for obtaining renewable energy from the waste. Our professionals have worked in different countries. We are also working in the sector of laser systems, solar panel, and textile and construction business.

World Market Scenario: Billions of wastages are available in all over the world. We can’t burn or land fills that tyres due to pollution problems. There is no any other use of these waste tyres. So, we at Anjali Exim have found a solution for this wastage tyre. We separate all content from wastage tyres and make it complete renewable process.


Features of the plant:

100% wastage tyre recycling is achieved (No churn left after the process)

No chemical ingredients are used in process (environment friendly)

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)

The most cost-effective wastage tyre recycling technology in the world.

Raw material (wastage tyre) is cheap and easy to provide. These are the by-products of

tyre production.

Each recycled ton of tyres preserves 10 tons of CO2 that is a major green house gas.

The process can be applied to all rubber based materials.

The system creates an alternate source of energy to replace petroleum products and

natural gas.

System gives the opportunity to governments and local administrations to deal with the

wastage tyre problem to a great extent.

The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and

size of tyre (car tyre, truck tyre, 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 as a fuel-oil in tanks.


The Features of the Fifth Generation Plant

Item. Picture. Features.

Catalyst Room

Two catalyst room, in this way, can speed up the process of pyrolysis.

Horizontal Condensor

Two horizontal condenser, the cooling area of one horizontal condenser can be equaled with more than three vertical condensers. And also, the cooling way is longer than vertical condenser, in this way, the oil output will be guaranteed.

Vertical Condensor

Another two length cooling pipes, the cooling area can be equaled with one vertical condenser, in this way, the cooling result will be better than our fourth Generation.

Anti back devices

Two anti back fire devices, it is our second water seal, and also reuse the exhaust gas as burning material, two anti back fire device, more safety, more energy saving.

The exhaust Gas

From the picture, you can see the exhaust gas, it is white, no pollution, even if you put a white towel on it you cannot see any black. It can meet the emission standard of international required.


The Perfect Solution (Pyrolysis Process): Pyrolysis is the decomposition of organic compounds under oxygen free (anaerobic)

atmosphere that produces gas, oil, carbon black and steel. Efficient industrial Pyrolysis is a process to treat the rubber and industrial plastic wastage as well.

As a result of pyrolysis of wastage tyres one obtains,

FUEL OIL (45% to 50%)

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 45% to 50% of the amount of recycled scrap tyres, which will be carried with licensed tanker trucks.

CARBON BLACK (30% to 35%) Carbon Black is the main product recycled by Pyrolysis technology. The amount of

recycled carbon black is 30% to 35% (depending on the type of tyres) 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.

Carbon black produced by Pyrolysis process (CBp) is more economical compared to

carbon black produced primarily from petroleum and is more price-efficient to be used as an ingredient in the industries listed;

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 Industrial rubber products Fire fighting


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.

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.

It can be replaced where natural gas and propane are stored.

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 10 ton scrap tyre/day recycling capacity, the facility generates 500 - 800 m³/day gas, which has an enormous energy potential when evaluated.


5th Generation photo:


PYROLYSIS CARBON BLACK TEST REPORT:


PYROLYSIS FURNACE OIL TEST REPORT:


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 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 re-

circulated through process. These systems can be operated 24/365.

AZ – 150 Tyre Recycling Plant:


AUTO FEEDAR:

NEW DESIGN OF CARBON VACUUM SYSTEM & CHIMENY :


Process Flow Chart:

Scrap Tire

Stocking

Pyrolysis Unit

Oil Carbon Black Steel Wire Gas

Storage Sleve Sleve Burning Unit

Transfer to

Refinery

Carbon Black Storage Chimney

Storage

Magnet

Grinding System

Packing

Stowing

Sale to Market

Pressing

Transfer to

Scrap Dealer


Technical Parameter:

Project ( Dimension : 6.6 *2.6m)

Sr. No. Equipment Specification

1 Equipment Model AZ-150

2 Material Plastic rubber (tyres) life garbage

3 Structure Horizontal tyre revolves

4 Capacity For One Batch About 8-10 tons wastage tyres

5 Oil Yield 45%-50%

6 Carbon Black 30%-35%

7 Steel Wire 10%-15%

8 Gas 5%-8%

9 Work Pressure Normal

10 Main Engine Rotation Speed 0.4 RPM

11 Fuels Choice Coal, Wood, Gas, Oil

12 Power About 35 HP

13 Cooling Method Water

14 Cooling Water Consumption(T/H) Cyclic

15 Type Of Drive External Annual Gear Drive

16 Heating Method Direct

17 Type Of Installation With Foundation

18 Operating Mode Intermittent Operation

19 Reactor Dimension (MM) (Long*Diameter) 6600*2600

20 Reactor Weight About 22000 Kg.

21 Total Weight About 32 MT


5th Equipment List D = Diameter L = Length H = Height W = Wide

Name Weight Size (MM) Quantity Picture

Reactor 22000 kg D2600*6600 1

Catalyst Chamber H2100*L1800 1

Oil Water Separator

D1200*H2100 1

Oil Tank D1000*L3200 2

Horizontal Condenser

D1050*L400 2

Vertical Condenser

300kg D800*L2600 2

Anti-back fire device

50 kg D400*H1350 2

Buffer Tank 50 Kg D550*H1350 1

Negative Pressure Device

890 Kg H2050*W2000 1

Water Jet Flue D500*L4000 1

Dust Removing device

2000kg H1250*L2950 1

Draught Fan L950*W800 1

Chimney 200kg 20FT 1

Auto Feedar 400Kg L4700*W1200*H2150 1

Releted link pipe


Difference Between Fourth Generation And Fifth Generation Tyre Pyrolysis Plant

Name 5th Generation Tire Pyrolysis Plant 4th Generation Tire Pyrolysis Plant

Catalyst Chamber

We call the 5th catalyst chamber “double chamber “. This design could add the molecular sleve , which increase the oil quantity, beside these are two catalyst chamber could reach double effect of catalytic pressure and remove the slag from the oil gas.

Oil Water Separator

The Oil Water Separator new design could have the colling cover that cool the gas so that decrease the temperature of the oil gas, than the oil gas could be more easily collected in next stage.

Condenser

The condensers are changed as horizental , this could incersase the colling area, so that more oil gas could be colleted , thes the oil yiekd are higher the oil yield rate could reach 53%.

Oil Tank

The oil capacity is bigger than tha 4th generation and it could be equipped with the automatic pumping system.


Anti – back fire Device

Double anti-back fire device could be recyeled the tail gases more sufficently so that the

reactor could burn more gases us fule to save energy and will not pollute the air , so that more enviromental friendly. Also there are two pipes colling the tall gas to that more safe, as the fule gas are usally methane , eathane, hydrogen etc, if the temperature is so high then it easy to blast.

Carbon black Removing Equipment

Our R&D department invent this bucket elevator to lift the carbon black into the come pool automatically, there is no need manpower ot lift, and also there is a Air compresser to cool the hot carbon black then this save time to collect the carbon black.

Electric Controller

5th generation electric has two function, one is the control the power and another showing the temprature of the oil out, 4th generation electric could only control the power.


Project Planning & Implementation (For the 10 ton/day capacity): Land Requirement : 1500 sq. meters Construction Shade : 40Ft * 80 Ft = 3200 Sq.Feet Water Required : 1000 liter per day Power Requirement Without Autofeeder : 20 hp With Autofeeder : 35 hp Man Power Planning : Manager-2 Technical-1 Worker-4

Capital investment:

Other Arrangements to be made by Client Storage tank Of oil (Available locally),Civil Work, Local Worker & labor ,Hydro crane, Plumber, Electrician, Gus cutter, Welder.

Terms & Condition: Delivery Time :Chinese plant 30 days from your order confirmation Installation Period :15 days Warranty Period :1 Year After Sales Service :6 Month Free Service after then AMC Based… Installation, Training & :Inclusive in price.

Particular Investment

Building and land (1500sq.meter with 600sq.meter shade) Depend on the area

CHINESE PLANT

Price of the Plant (Ex – Factory China) 5th Generation With Auto feeder

( Dimension:2.6*6.6MT) 65,000 USD

Price of the Plant (Ex– Factory China) 5th Generation Without Auto feeder

( Dimension:2.6*6.6MT) 60,000 USD

Custom Duty 26%, Fright, Container Clearing Charges, Transportation Extra.

This does not include the rate of interest on capital investment.


Estimated Operational Cost and Return on Investment:

The analysis is based on the conjecture of 10 tons/day capacity unit operating for 300 days a year; Raw material waste Tyre: 8 ton per day*300 days = 2400 ton/ year.

Total output:

Carbon black (30%) - 720 Ton (Rs 1,000 per Ton in India)

Furnace oil (45%) - 1080 Ton (Rs 35,000 per Ton in India)

Steel (12%) - 288 Ton (Rs 12,000 per Ton in India)

Gas (8%) - 192 Ton (We are not considering price of it right now)

Total Earning: (Yearly) (Unit: Tons)

Sr. No Product Output (%) Output (Ton) Price Per ton. Total Income

1 Carbon Black 30% 720 1,000 7,20,000

2 Furnace oil 45% 1080 35,000 3,78,00,000

3 Steel 12% 288 12,000 34,56,000

4 Gas 8% 192 --- 0

Total (A) 4,19,76,000

Total Expense: (Yearly) (Unit: Tons)

Sr. No Particular Quantity Price Total Cost

1 Waste Tyres 2400 12,000 2,88,00,000

2 Salary & Wages 9*12 Month 10000 10,80,000

3 Fuel (For Initial Use) 300 5000 15,00,000

4 Electricity + Water --- -- 7,20,000

5 Misc. Expense (Bag Packing, Repairing, Renovation)

--- -- 9,50,000

Total (B) 3,30,50,000

Profit (Earning – Expense) (A-B) 8,926,000


520-527, PODDAR ARCADE,

KHAND BAZAAR, VARACHHA ROAD,

SURAT, 395006

GUJARAT, INDIA.

Phone: +91 261 2554152

Fax: +91 261 2554149

Web: www.anjaliexim.com

Email: [email protected]

Thank You . . . !

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5th generation waste tyre recycling...

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