Plastics and EOL (End of Life) Tyres Recycling Plant

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Description of the process, the equipment required

Pyrolysis Plant
It is a commercially proven technology that produces high quality fuel and other renewables from waste material. The computer controlled automatic plant uses reverse process technology to pyrolyze and deoxidize tyres and plastics into liquid fuel oil. This oil automatically processed into Diesel fuel and bitumen (plastics feed stock), or Diesel fuel, carbon black and scrap steel (EOL tyres shredded feed stock), and a smaller amount of non-condensable fuel gas. The whole production process is in an airtight environment. The gas is treated by physical and chemical methods in the process to eliminate its polluting characteristics.

Processing

starts with conveying the feedstock into the auto-pyrolysis reactor by an automatic feeder through a heat/airtight device. Due to the reverse process technology no other material added, no need for catalyzer. In the reactor the material is cracked by pyrolysis reaction under normal pressure and at a low temperature. The produced pyrolysis gas then further processed in the fractioning tower into Diesel oil and a small amount of combustible gas. The gas is treated in the purifier then returned into the process as fuel for the specially designed burning device which assures constant temperature for the reactor. Residues from the whole process are refined by air- and magnetic separator, and deoxidization is in special environmentally friendly nano-carbon black equipment.

Plastics Feed stock does not need to be sorted, washed nor shredded. The plant can recycle PET, PETE, HDPA, PVC, LDPE, PP, PS and ABS plastics mixed, without separation. However, if any non-plastics gets in the feed stock fuel output will be lower.
The heat requirement for the cracking in the Pyrolysis process totally provided by the combustible gas, as it is reused in the environmentally friendly burning device; external energy required only for start-up then nothing at all. The filtering system for exhaust gases will clean the emission to reach international standards before being discharged.

Plant capacity

The proposed facility will process 10 tons of EOL tyres or plastics per day, totaling to 3300 tons per year. The plant can work continuously for six months then maintenance required, for that and possible switching over between tyres and plastics, if required, 35 days down-time allowed. To be noted: plastics and tyres feed stock can’t be mixed at any time!

 
Shredder
For EOL tyres processing starts with shredding then pyrolysis begins as it was described. The process starts conveying the tyres into the shredder, max. 1mtr diameter tyres allowed, where they shredded into 15-20cm pieces. In the second phase these pieces further shredded into appr. 2cm size. In the third phase rubber is separated from the steel waste, 80% of the 15% steel content removed. The remaining 20% will be removed by the magnetic separator in the Pyrolysis plant.

Briquette line
An output from tyre recycling is carbon black, a relatively clean carbon with high heating value. According to tests the value is 30.0+ MJ/kg which equals 7164 kcal/kg. The briquette line processing this carbon into highly commercial value added ‘smokeless’ briquette, start-up fuel for foundries, to fire industrial boilers or used as barbecue fuel briquette. In the process 15kg environmentally friendly binder added to one ton of carbon black, the additive is cheap natural product.
Estimated equipment cost

Pyrolysis Plant
10 ton/day capacity design,  GBP 2.2 million (larger plants are available on request)
Price includes equipment, shipping, installation, forklift
Shredder
1.5 ton/hour capacity,  GBP 310,000
Price includes equipment, shipping, installation, forklift

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Briquette line
2 ton/hour capacity,  GBP 220,000
Price includes shipping, installation, forklift
Estimated space required for equipment and estimated labour requirement

Pyrolysis Plant
L 20m x W 9.2m x H 6m
Lower skilled workers 2-3, shift supervisor included
Training will be provided

Shredder
L 21m x W 2m x H 5.5m
Low skilled workers 2-3, shift supervisor included
Training will be provided

Briquette line ( Also available Activated Carbon)
L 38m x W 2m x H 3.5m
Lower skilled workers 2-3, shift supervisor included
Training will be provided
Sizes indicated are equipment sizes, to estimate total space required 2-2 meters should be added to each side and to both ends. As the plant uses conveyor belts between processing phases it is not possible to go upwards and shorten the lengths.

Option
Prefabricated ready to erect buildings are available, especially designed for each plant equipment.
Energy requirement
Pyrolysis plant
Total power requirement  30-50kW input
Shredder
TPR  320kW input
Briquette line
TPR  95kW input
For daylight operation and area lighting solar power generation can be utilized, 500kW system is available.
Plant outputs and estimated commercial value
From 3,300 tons of plastics and EOL tyres the plant will produce (yearly):

Tyres
1,155 tons of high grade Diesel fuel, appr. 1.444 million litres
    Value @1.32/ltr = GBP 1,906,080
1,221 tons of briquette
    Value @7.99 for a 4kg bag of barbecue briquette = GBP 2,438,947
429 tons of scrap steel
    Value @100.00/ton = GBP 42,900
132 tons of water (recycled)
297 tons of gas (reused in the system)
66 tons of impurities (neutral salts, can be used as fertilizers)

Plastics
2,310 tons of Diesel fuel, appr. 2.888 million litres
    Value @1.32/ltr = GBP 3,812,160
    To be noted: if non-plastics get into the feedstock Diesel output will
    decrease and bitumen output will increase!
1,500 tons of oil refinery quality bitumen
    Value @250-300/ton = GBP 375,000
510 tons of water, gas, impurities: as above

To sum up, the total output value from 3300 tons of

EOL tyres  appr. GBP £4.38million +

Plastics     appr. GBP £4.18million +