Contents

Approvals Applied for7

About RAYS ENSERV35

About Our Technology36

Our Expectations from PEDA38

Plastics

Thermo-SetsCan be used only once.Cannot be recycledPolyurethane, Epoxies, Polyester etc

Thermo-PlasticsNo Chemical change with Temperature.Can be recycled many times.Molecular Weight 20000-50000PP, LDPE, HDPE etc

PlasticsPetrochemicals

Natural Decomposition– 400 to 600 years

Production–2013 :

PE43 %

PVC28 %

PP 24 %

Global 299 MMTIndia 8.5 MMT

PS3 %

Others2 %

Incineration

Landfilling

Conversion

Recycling

ThermalDecomposition

Gasification

Recycling of Thermoplastics can be done 3-5 times

Release of toxic

Gases

AIncineration

Create Value Added Products

DThermal

Decomposition

Making RoadsRail Carpeting

CConversion

Requires large area

Land becomes infertile

BLandfilling

Disposal of Waste Plastics

Thermal Decomposition

Waste Plastics

Incineration1100 0C with Air

Power, Flue Gas,Ash

Gasification800 0C with limited

AirSYNGAS, Ash

Pyrolysis500 0C with no Air

Oil, Gas and Char

Different Processes

Effective conversion of high molecular weight polymers into lower molecules, Net energy recovery is HighProducts have huge demand, Low capital and operation cost.

Conversion of high molecular weight polymers into basic molecules of CO and H2, High energy input requirements, Capital cost is very high

Incineration Gasification Pyrolysis

High Quantity of Dioxins and Furans,Low thermal efficiency, high quantity of ash generation and flue gas emissions and generation

Pyrolysis

� Pyrolysis Technology may be defined as thermal decomposition/cracking oforganic waste (in the absence of air having inert environment) to produceuseful energy products. Pyrolysis Reactors can be Fluidized Bed, Fixed Bed,Rotary Kiln

� Pyrolysis Technology may be defined as thermal decomposition/cracking oforganic waste (in the absence of air having inert environment) to produceuseful energy products. Pyrolysis Reactors can be Fluidized Bed, Fixed Bed,Rotary Kiln

Technology Residence Time Heating Rate Temperature (oC) ProductsSlow Pyrolysis Hours – Days Very Slow 300 – 500 CharcoalConventional Pyrolysis

5 – 30 Minutes Medium 400 – 600 Oil, Gas, Char

Conventional Pyrolysis

5 – 30 Minutes Medium 700 – 900 Gas, Char

Fast Pyrolysis 0.1 – 2 Seconds High 400 – 650 Oil, Gas, CharFast Pyrolysis < 1 Second High 650 – 900 Oil, Gas, Char

< 1 Second Very High 1000 – 3000 Gas, Char

Pyrolysis

� Change in product composition with Temperature

Temperature 0C

Wt.

%

� Change in product composition with Pressure

Pyrolysis

Part of polymer chain breaks at two locations

Remaining ends of polymer chain need hydrogen

The part of the polymer chain removed either needs hydrogen or

Shortens the chain, depositing carbon (char)

Pyrolysis Enthalpy of Reaction

The heat (enthalpy) of gasification is thedifference between the enthalpy of the solid inthe initial state at ambient temperature andpressure, T0 and P0, and the enthalpy of thevolatile thermal decomposition products at Tpand P0. If the stored heat is ∆hs, the enthalpyof fusion (melting) for semicrystalline polymersis ∆hf, the bond dissociation enthalpy is ∆hd,and the enthalpy of vaporization of thedecomposition products is ∆hv, then theenthalpy of gasification per unit mass of fuel is

Lg = ∆hs + ∆hf + ∆hd + ∆hv

The symbol Lg derives from latent heat, i.e., the recoverable heat in a reversible process

PE PP PS

∆hs (J/g) 803

∆hf (J/g) 243

∆hd (J/g) 910

∆hv (J/g) 345

Lg = Σ ∆hi (J/g) 2301 1900 1800

Energy Density

Material Calorific value (MJ/kg)

Polyethylene 46.3

Polypropylene 46.4

Polystyrene 41.4

Polyvinyl chloride 18.0

Coal 24.3

Liquefied petroleum gas 46.1

Petrol 44.0

Kerosene 43.4

Diesel 43.0

Light fuel oil 41.9

Heavy fuel oil 41.1

Old Process

National & International Efforts

About RAYS ENSERV

Partnership Firm having professionals from diverse fields

Working on the project from the last 5 years

Developed and operated batch type pilot planthaving 500 kg/batch capacity. Developed acontinuous commercial scale plant

¾ Plant to be installed in 2 phases;

¾ Phase 1 - Technology demonstration unit¾ of 10 TPD Refuse Derived Liquid Fuels¾ (RDLF) and syngas plant

¾ Phase 2 - 10 TPD Refuse Derived Liquid¾ Fuels (RDLF) and syngas plant

Our Proof of Concept Plant

Our Process

OURConcept

Advance Thermal Treatment Process

Dewatering

Drying

Storage

Oil/ Gas Separation

Storage

Cleaning

Shredding

Receipt

Feedstock PreparationProcess

Melting

Supercritical Catalytic Plate

Reactor

Vapor/Solid Separation

CHAR

GAS

OIL

Mass Balance

Raw material cleaning(30 MT)

Raw material dewatering(20 MT)

Raw material drying(17 MT)

Raw material (30 MT)

Feedstock melting(15.5 MT)

Supercritical Catalytic Plate Reactor (15 MT)

Vapor/solid separation(15 MT)

Condensation(10 MT)

Oil/Gas Separation(10 MT)

Storage of Oil (9 MT)Organic fibers with

moisture (10 MT)

Water for reuse/plantation(3 MT)

Moisture into atmosphere(1.5 MT)

Gas to Generator(1 MT)

Char with inert(5 MT)

Moisture into atmosphere(0.5 MT)

Work in Progress

Our Technology

Our Technology

ProtectionSafety

Efficiency

Advanced Control

Highest Quality

Advanced Operation

Modular Zero Emission

Expandable

Advanced Logic

Multipoint Redundancy

World Class Technology

Energy Balance (Each Phase)

Electricity 1.1 KW/kg. of feedstock

15 MT (15000 * 1.1)/24 = 687.5 KWH

Heating mechanism for the process

Electrical energy requirement

Daily finished dry raw material processing

Hourly power requirements

11000 Kcal/kg.

Calorific Value of RDLF and Syngas

10 MT/day

Daily RDLF and Syngasproduction

Energy Balance (Each Phase)

10000 * 11000 = 110000000 Kcal 2.4 Mweq (Each Phase)

2400 – 700 = 1700 KW (15000 * 1.1)/24 = 687.5 KWH

Gross Energy production

Equivalent Electrical Energy Generated

Surplus net energy from project (Each Phase)

Equivalent Electrical Energy Generated at 45% efficiency

Excellent fuel for boilers, furnaces/brick kilns

Char and Organic Fibers generated @ 10 MT/Day (on dry basis) having calorific value of 3500Kcal/kg

Emissions

1Water Consumption – washing, cooling

and domestic purposes

Wastewater Generation –

Washing operations and domestic use

3

No solid waste generation

Residue from feedstock preparation

to be used as byproduct for other

industrial use

2

No process emissions

Air emissions only in the form of D G

set exhausts

Water and Wastewater Air Emissions Solid Wastes

Fire Fighting Facility

¾ Installation of Fire Alarm System within the factory premises¾ Separation of RDLF storage area in the plant by firewall . AFFF concentrates (Aqueous Film-

Forming Foams) would be used as fire fighting agent in the process and oil storage area.¾ All openings for switchgears and cable entry to be sealed by fireproof seals, static bonding of

pipeline flanges, all flameproof pumps to be installed, jumper connections to prevent build up ofstatic electricity charge, double earthing of all electric motors

¾ Reserve storage of 50 m3 of water to cater water requirements of the fire protection system¾ Installation of two pumps, each of 20 m3/hour capacity to keep the hydrant and HVWS systems

mains pressurized.¾ Fire hydrants to be provided in all the areas of the industry¾ HVWS system to be provided in the fuel storage area¾ Provision of wall/column mounted portable fire extinguishers in various areas of plant including

control room, admn. building etc.

Personnel Protective Equipments to be provided for the safety of manpower in theindustry

• Goggles – during washing of raw material

• Full suit having hand gloves, goggles, helmet and aprons would be provided to

persons handling Oil and Char

• Face shield helmet would be provided for welding works

• Emergency medical facilities would be provided in the industrial premises having

first aid box in the factory

• Regular six monthly medical check up of all the personnel working within the

factory premises.

Occupational Health and Safety

¾ Application filed in PEDA for approval of Project

¾ Combined Application submitted in Invest Punjab for all state department approvals

Statutory Approvals

¾ VAT exemption on raw material purchase and sale of products for the project

¾ Electricity Duty and Octroi exemption on power being utilised by the industry

¾ Income tax exemption

¾ Excise Exemption on the sale of products

¾ Exemption from Stamp Duty and CLU for the project

¾ Central financial assistance as applicable to the project

¾ Availability of leased land by PEDA for future expansion of the project

Incentives Expected from PEDA and MNRE

If you can see the invisible You can make the impossible