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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]