“Bringing You & Technology Together“
th
5 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
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. Catalyst Room
Picture.
Features. 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, cooling area can be equaled with vertical condenser, in this way, cooling result will be better than fourth Generation.
the one the our
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 Plant 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 recirculated through process. These systems can be operated 24/365.
AZ – 150 Tyre Recycling Plant:
AUTO FEEDAR:
CARBON REMOVAL SYSTEM:
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
Magnet
Storage
Pressing
Transfer to Scrap Dealer
Grinding System
Stowing
Packing
Sale to Market
Chimney
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
Reactor
22000kg
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
1
Anti-back fire device
50 kg
D400*H1350
2
Buffer Tank
50 Kg
D550*H1350
1
Negative Pressure Device
890 Kg
H2050*W2000
1
D500*L4000
1
H1250*L2950
1
L950*W800
1
Water Jet Flue Dust Removing device
2000kg
Draught Fan Chimney
200kg
Auto Feedar
400Kg
Releted link pipe
1 L4700*W1200*H2150
1
Picture
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 screw conveyor 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 Construction Shade Water Required Power Requirement Without Autofeeder With Autofeeder Man Power Planning
: : :
1500 sq. meters 40Ft * 80 Ft = 3200 Sq.Feet 100 liter per day
: : :
20 hp 35 hp Manager-2 Technical-1 Worker-4
Capital investment: 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) Price of the Plant (Ex– Factory China) 5th Generation Without Auto feeder ( Dimension:2.6*6.6MT) Custom Duty 26%, Fright, Container Clearing Charges, Transportation Extra. Shredder Price ( 2 ton/ hr Capacity)
70,000 USD
64,000 USD
Rs. 25 Lakhs
This does not include the rate of interest on capital investment.
Other Arrangements to be made by Client Storage tank Of oil (Available locally),Civil Work, Local Worker & labor
Terms & Condition: Delivery Time :Chinese plant 30 days from your order confirmation Installation Period :15 days Warranty Period :1 Year After Sales Service :1st Year Free Service after then AMC Based… Installation, Training & :Inclusive in price.
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 (35%) Furnace oil (45%) Steel (12%) Gas (8%)
- 840 Ton (Rs 1,000 per Ton in India) - 1080 Ton (Rs 38,000 per Ton in India) - 288 Ton (Rs 12,000 per Ton in India) - 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
35%
840
1,000
8,40,000
2
Furnace oil
45%
1080
38,000
4,10,40,000
3
Steel
12%
288
12,000
34,56,000
4
Gas
8%
192
---
0
Total (A)
4,53,36,000
Total Expense: (Yearly)
(Unit: Tons)
Sr. No
Particular
Quantity
Price
Total Cost
1
Waste Tyres
2400
10,000
2,40,00,000
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)
2,82,50,000
Profit (Earning – Expense) (A-B)
1,70,86,000
Shredder Cost/ ton: 1) 2) 3) 4)
Cost of machine: Rs. 25 Lakhs Capacity: 48 ton/ day. Electricity consumption: 60 Hp. Labour = 3
Estimated Operational Cost: Capacity Utilization = 10 hr/ day
Total Expense: (Yearly)
(Unit: Tons)
Sr. No
Particular
Quantity
1
Electricity consumption
48 Hp
2
Salary & Wages
3*12 Month
Total Total Cost
• Plant require: 6000 ton/ Year. • So, per ton cost of shredding is Rs. 243/ ton.
Price
Total Cost Rs.11,00,000
10000
Rs. 3,60,000
Rs. 14,60,000 Rs. 14,60,000
Thank You . . . !
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]