FAB

Welcome to FAB INDIA Fab India Is a Pioneer in the Field Of Designing, Developing and Quality Manufacturing with more than 2o years experience situated at Ahmedabad, Gujarat. Fab India is a professional and high-tech company to product waste tyre recycling plant with a wide range (5 ton, 7.5 ton, 10 ton and 12 ton), good quality, reasonable prices and stylish designs, our products are used in many industries. This ISO 9001:2000 company has achieved this stature with over a decade of total commitment and continuous improvement and introduction of new products. Fab India follows the globally approved QMS (Quality Management System).

COMPANY PROFILE

Established in the year 1991, we “fab India” are a Dominant firm involved in manufacturing, supplying and installation Pyrolysis Equipment and Waste Tyre Recycling Plant. We also have our 3-manufacturing unit, which has been operating since 1993 regarding pharma, chemicals, minerals, food processing, textile etc. Moreover, This ISO 9001:2000 Company has introduced the most viable process for recycling plastic scrap and used tyre into fuel oil, carbon black, steel wire and gas (a carbon black product, which is a key component used for manufacturing new tire). Our Eco-friendly technology has been known for transforming over 10 billion squirrel away tyres around the world into energy. At our ultra modern infrastructure, we have been manufacturing a premium range (? 13 to 15) of recycling equipment. We are known for providing complete recycling solutions to clients with proven technologies. Along with this, we possess vast experience in Designing, Developing and Quality of equipment, along with technical analysis. Our pyrolysis plants are constructed & examine under the Diligence of our qualified experts, who ensure to dispatch only a qualitative range to customers. We also provide customized solutions to clients as per their specifications. Under the constant support of our Director, ‘Mr. Suresh Patel’. We have been growing in the industry. His tremendous knowledge, leadership, expertise skills and experience has enabled us to export our products to all over India.

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v Fab India’s workshop

Pyrolysis process

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• Pyrolysis can be used to reprocess the tyres into fuel gas, fuel oil, solid residue (steel wire) and carbon black.

• A pyrolysis method, which produces activated carbon and high-grade carbon black.

• The waste tyres are mainly composed of long chain of C-H molecules.

• The major source is from process of pyrolysis, separation and compounding of Oil.

• The technology of pyrolysis, cracking, and monomerisation of used tyres is always a hot topic.

v Tyre pyrolysis

The pyrolysis method for recycling used tyres is a technique, which heats whole or shredded tyres in a reactor vessel containing an oxygen free atmosphere and a heat source.

In the reactor the rubber is softened after which the rubber polymers continuously breakdown into smaller molecules.

These smaller molecules eventually vaporize and exit from the reactor.

These vapors can be burned directly to produce power or condensed into an oily type liquid, generally used as a fuel.

Some molecules are too small to condense. They remain as a gas which can be burned as fuel.

The minerals that were part of the tyre, about 40 to 45 % by weight, are removed as a solid.

When performed well a tyre pyrolysis process is a very clean operation and has nearly no emissions or waste.

The properties of the gas, liquid and solid output are determined by the type of feedstock used and the process conditions.

For instance, whole tyres contain fibers and steel. Shredded tyres have most of the steel and sometimes most of the fiber removed.

Batch wise Process is done by tyre pyrolysis.

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The steel can be removed from the solid stream with magnets for recycling. The remaining solid material often referred to as "charcoal".

v Variety of polymer waste material is suitable as a raw material. Given below is the list of suitable raw materials for pyrolysis:

ü Waste tyres

ü Rubber or rubber parts from vehicles

ü Electronic scrap

ü Mixed waste from waste paper mill

ü Mixed (HDPE, LDPE, PE, PP, Nylon, Teflon, PS,ABS,FRP etc)

ü Multi layered

The choice of feedstock and process can impact the value of the finished products

v Input-output ratio of waste tyre

Input Material Input Quantity Output quantity

Nylon scrap tyres 1000kgs -400 to 450 lit of Pyrolysis oil

-50 to 80 kg of Hydrocarbon Gas

-300 to 350 kg of Carbon Black

Redial scrap tyres 1000kgs -400 to 450 of Pyrolysis oil

-50 to 80 kg of Hydrocarbon Gas

-300 to 350 kg of Carbon Black

-150 to 200 kgs of Mild steel tyre scrap

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v Yield(End product) of pyrolysis process:

Pyrolysis oil (Fuel oil)

• The essential product of tyre pyrolysis process is pyrolysis oil referred as fuel oil

(40 to 45 % of total quantity feed) which is used as a fuel component for heating oil’s and as a component in vessel fuels.

• Purest quality of pyrolysis oil comparable to industrial diesel: selling price comparable to industrial diesel LDO( light diesel oil)

Carbon Black

• The vital product of pyrolysis plant is carbon black referred as "charcoal"(30 to 35% of total quantity feed).carbon black has Industrial and commercial use.

Steel wire

• For instance, whole tyres contain fibers and steel. Shredded tyres have most of the steel and sometimes most of the fiber removed.

• The steel wire (15 to 20%) can be removed from the carbon black with magnets for recycling after pyrolysis process & sold to the steel dealer

Hydrocarbon Gas

The smaller molecules eventually vaporize and exit from the reactor. These vapors can be burned directly to produce power or condensed into an oily type liquid, generally used as a fuel. Some molecules are too small to condense. They remain as a gas (5 to 8% of total quantity feed) which can be burned as fuel.

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Pyrolysis plant

Pyrolysis plant is renewable energy generation system. Pyrolysis plants are designed to generate quality fuel from polymer waste. Pyrolysis system or pyrolysis plant is an industry for conversion of waste and tyre into usable products like:

• Pyrolysis oil(Fuel oil) • Carbon black • Steel wire • Hydrocarbon gas

v Advantages of pyrolysis plants • Purest quality of pyrolysis oil as finished product. • Use of green technology to achieve environment friendly processes. • Automatic safely valve use to improve safely, profitability & ease of operation. • Industry is energy self-sufficient. • No external fuel required for heating.

v Benefits of pyrolysis plant • Recover energy and value from waste in form of fuel and charcoal. • Reduce tyre land pollution. • Eco-friendly recycling of tyre. • Commercially viable process. • End product is used as substitute to LDO/furnace oil. • Perfect solution for polymer waste management. • Raw material available.

v Bas ic function of pyrolysis plant is to achieve following process conditions: • Operating temperature of Reactor is between 300 to 350 degree c. • Duration period of pyrolysis batch is between 7 to 9 hours. • Pyrolysis of tyre is done in the absence of oxygen. • Scrubbing of pyrolysis oil, hydrocarbon gases and fuel gases to prevent pollution.

v Pyrolysis plant needs following machinery & equipment: • Raw material handing section.

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• Pyrolysis reactor.

• Hydraulic cutter. • Hydraulic auto feeder.

• Condensation system.

• Scrubbing system.

• Hydrocarbon gas cleaning & storage system. • Pyrolysis oil storage system.

• Cooling tower.

• Control panel and alarm systems. • Equipment line in commercial pyrolysis plants is further modified to suite customer’s

requirements.

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v B.Q.Plates SA 516 Gr.70 Test Report

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v Flow chat for pyrolysis process

Waste tyre (Nylon/Radial tyre)

Deliver

Pyrolysis plant

Pyrolysis process

Steel wire Carbon black (charcoal) with small particle of steel wire

Pyrosis oil (Fuel oil-LDO)

Hydrocarbon gas

Magnate & sleeve

Storage

PYROLYSIS OIL STORAGE system

Recycle burning Unit

Carbon black

Compressed

Chimney Storage

Deliver to refinery unit

Transfer to scrap dealer

pulverizer system

Collect

Sale to market

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Technical detail of 10 ton PYROLYSIS PLANT

Sr No

Item Contraction Description

1

Main(10 ton) Reactor 14 MM BQ Plate Capsule Type

6.6 Miter x 2.6 Miter 14 MM Plate Thickness

2 Verticals Condenser

OR

pipe condenser

5 MM MS Plate

OR

4” MS Pipe 20 Nos C Class Pipe

600 x 2000 MM 4 Nos

OR

4” Pipe 20 Nos withHeader 16” x 1500 MM

3 Insulation tank 5 MM MS Plate 800 MM x 1500 MM cera wool insulation with aluminum sheet

4 Water seal tank 5 MM MS Plate 1000 MM x 1800 MM

5 Gas tank 5 MM MS Plate 800 MM x 1550 MM

6 Oil Tank 5 MM MS Plate 800 x 2250 2 Nos 800 Liter x 2 Nos

7 Water coolant pipe 8 ” OD Pipe covered with 12” Water coolant pipe

10 FEET length

8 Dust pipe 12”Pipe -3 Nos pipe (1), 10 feet pipe (2), dust washer pipe (3)S, scrubber to blower pipe

9 Scrubber Tank 5 MM MS Plate 800 MM x 2750 MM with coolant pipe

10 Dust Blower 5 MM MS Plate 5 HP Blower with Motor

11 Hoist 2 HP HP 4” Reduction gear Hoist

1 Tons wire Hoist with Motor

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12 Chain block 2 Tons Chain block 2 Tons chain block with 10 Feet chain for reactor door

13 Penal board Reactor Penal board with 10HP VFD Drive

Total motor Controller temp indicator penal board

14 Submersible Water pump

3 HP Submersible pump Atlas Brand 3 HP Sub Pump for cold water supply

15 Gear pump 3 HP Gear pump Atlas Brand 3 HP Gear Pump for oil transfer 16 Mud pump 3 HP Mud pump Atlas Brand 3 HP Mud for scrubber systems

17 Chimney 12” Pipe chimney 20 Feet for chimney pipe 18 Gas Blower 2 Nos Gas blower 0.5 HP 2 Nos Reactor Gas blower 19 Extra gas burner 1 NOs Gas burner Extra Gas Burner 20 Cooling tower Capacity 50 tons 3 HP 2880 RPM Motor 21 Hardware As per annexure I Hardware for reactor pipe and pipe fitting 22 Reactor cover Reactor cover insulation With cerawool 1260 Temp 25 MM Two

layer 23 Electric Motor Standard make As per annexure II

24 Foundation As per drawing Price not including in basic Price

25 Reactor Gear box Shricon Brand 180 Center 10 HP Helical Gear 26 Fire Brick & Castable

cement 500 Nos Fire Brick and castable cement - 4+4 bags

For fire system

27 Hydraulic Auto feeder

5 MM Plate and 100 MM Channel

5 HP Hydraulic Auto Feeder, works with 40 tons hydraulic pressure

28 Hydraulic cutter 16MM MS PLATE 5 HP Hydraulic Auto Feeder, works with 40 tons hydraulic pressure

29 Material handing screw for carbon

8”PIPE COVERD with 12”PIPE(5MM) with cooling system

3 Hp motor WITH 4”GEAR,18 feet long

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v Assembly drawing for pyrolysis plant

v 3D drawing for pyrolysis plant

vFoundaton drawing will be send by us

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vTECHNICAL PARAMETER S.N Items Model Model Model 1 Equipment type FI - RF-5 FI - RF-7.5 FI - RC-10 2 Raw material Nylon / Radial Tyre Nylon / Radial Tyre Nylon / Radial Tyre 3 Structural form Horizontal rotation Horizontal rotation Horizontal rotation 4 24-hour Capacity 4.3 ton 6.5 ton 8 ton 5 Oil yield [ 40 to 45 % oil ] 1.94 ton 2.93 ton 3.6 ton 6 steel scrap [15 to 20 % ] 0.86 ton 1.3 ton 1.6 ton 7 Carbon [30 to 35 %] 1.29 ton 1.95 ton 2.4 ton 8 Operating pressure Normal ( 0.3 To 0.5

Kg) Normal ( 0.3 To 0.5 Kg)

Normal ( 0.3 To 0.5 Kg)

9 Material of Reactor B.Q.Plates SA 516 Gr.70

B.Q.Plate SA 516 Gr.70

B.Q.Plate SA 516 Gr.70

10 Thickness of Reactor 12 mm 12 mm 14 mm 11 Rotate speed of Reactor 0.4turn/minute 0.4turn/minute 0.4turn/minute 12 Total power 18KW 22KW 25KW 13 Mode of Water cooling Circular cooling Circular cooling Circular cooling 14 Cooling area of condenser 38 Sq.Meter 47 Sq.Meter 47 Sq.Meter 15 Kind of transmission VFD drive VFD drive VFD drive 16 Noise dB(A) =85 =85 =85 17 Size of Reactor(D×L) 2.2×6.0 Mt. 2.2×7.0 Mt. 2.6×6.6 Mt. 18 Working form Intermittent

operation Intermittent operation

Intermittent operation

19 Lend requirement Sq.Mt. Sq.Mt. 1500 Sq.Mt. 20 Delivery time within 2 weeks within 2 weeks within 2 weeks 21 Installation Time 10 to 15 Day 10 to 15 Day 10 to 15 Day

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CONTACT

FAB INDIA

PLOT NO.3/4, KHODIYAR ESTATE, NR.SHAKRIBA ESTATE, PHASE – IV, VATVA G.I.D.C, AHMEDABAD. Mobile No: +91 93270 23433 : +91 97250 12746. Office No : +91 8980014620 Tel No : +91 79 40301472. Skype ID: fabindia Email Id: fabindia2@gmail.com Web Site: www.pyrolysisplant.in