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WASTE TYRE PYROLYSIS - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue

With the phenomenal increase in number of automobiles in India during recent years the demand of tyres as original equipment and as replacement has also increased. As every new tyre produced is destined to go to waste stream for disposal or recycling or reclamation, despite its passage through retreading process, the number of used tyres being discarded is going to increase significantly. Timely action regarding recycling of used tyres is necessary in view to solve the problem of disposal of used tyres keeping in view the increasing cost of raw material, resource constraints and environmental problems including fire and health hazards associated with the stockpiles of the used tyres. The world generates about 1.5 billion waste tyres annually, 40 percent of them in emerging markets such as China, India, South America, Southeast Asia, South Africa and Eastern Europe. In India, all new vehicles have radial tyres, so now there are piles of radial tyres here. Analysis indicates that 0.6 Million Tons of tyres scrap is generated in the country annually. It is commonly accepted in the tyre industry that about one tyre per person per year is discarded. Since there is no industry group or governmental agency that monitors tyre disposal in the country, the best estimates that can be made are based on tyre production. So supply situation of scrap tyres is only going to improve in years to come as a result of growing vehicle population in India. Mandatory scrapping of all ELV (End of Life Vehicles), in metros by 2010-11 and across India by 2012-13 is also likely to ensure large scale availability of scrap tyres at select locations there by encouraging organized players. The management of scrap tyres has become a growing problem in recent years. Scrap tyres represent one of several special wastes that are difficult for municipalities to handle. Whole tyres are difficult to landfill because they tend to float to the surface. These stockpiles are also direct loss of energy and resources in addition to fire & health hazard and other environmental issues. The main constituent of a tyre is rubber and the largest single application of rubber is vehicle tyres. Also the requirement of tyre is directly related to growth of automobile. The production of automobiles is forecast to continue to rise and is indicative of buoyant economic conditions for tyre industry, but at the same time guarantee and annual discarded scrap tyre volume growing at the same rate as new tyre manufacture. Waste represents a threat to the environment and human health if not handled or disposed of properly. According to this hierarchy, the priority of any country should be to extract the maximum practical benefits from products and prevent and minimize the waste that is generated. Thus, strategies for waste disposal should focus on waste prevention and minimization through the ‘3 Rs’ - Reduce, Reuse and Recycle. Gasification/Pyrolysis are two related forms of thermal treatment where Waste materials are heated to high temperatures with limited oxygen availability. Tyre to Energy Alternatives Tyres have a fuel value of 12,000 to 16,000 Btu per pound, slightly higher than that of coal. With existing technology, tyre combustion can meet environmental requirements. Combustion facilities currently using tyres as fuel include: Power plants, Tyre manufacturing plants, Cement kilns, Pulp and paper plants & Small package steam generators etc. Waste Tyre Pyrolysis: Pyrolysis of tyres involves the application of heat to produce chemical changes and derive various products such as carbon black, fuel oil, steel wires and combustible gases. The history of tyre pyrolysis projects to date indicates that the problems blocking them have been technical and economic. These include the problems of upgrading the carbon black by-product while keeping down the operating cost of the process and the capital cost of the plant. Recently, there has been a technical advance in char upgrading which have helped tyre pyrolysis economically feasible. Given below is the Input to Output ratio: Input Material: Waste Tyre Input : 1000 Kgs Output - 450 lit of Industrial Fuel oil - 125 Kg of Petroleum Gas - 330 Kg of Carbon Black - Up to 110 Kg of Steel wires Output is fuel oil which is mixture of petrol, diesel and kerosene. This Fuel oil can be directly used in boilers, generators, thermic fluid heaters, hot air generators, hot water generators, Furnace etc. Economics A preliminary cost analysis for a proposed tyre reprocessing unit is done on the following formula which is used to evaluate process economics. The process is highly profitable even for a small to larger unit capacity. The following formula is used to evaluate the process economics: P=F+R-C-T-S-D Where P is the profit, F is the tipping fee collected for tyre disposal, R is the revenue received from the sale of products, C is the processing cost of transportation of tyres, S is the cost of tyre cutting or shredding, and D is the cost of disposal of waste products. A small unit for tyre pyrolysis can cost from Rs 3.5 Crores to Rs 4.0 Crores depending on the capacity of the unit. This capital cost of investment will increase as the capacity of the unit increases. Conclusion Tyres should be utilized to minimize environmental impact and maximize conservation of natural resources. The management of scrap tyres has become a growing problem in recent years. But the pyrolysis technology has a great potential for using a major portion of scrap tyres generated each year, and actually reducing the tyre stockpiles that is in other words to convert waste stream of tyres into marketable products. Waste tyre pyrolysis has indeed identified existing and potential source reduction and utilization methods which will be effective in solving the tyre problem in the coming years.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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CARBON BLACK FROM WASTE TYRES (WASTE TYRE PYROLYSIS) - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Production Schedule

With the phenomenal increase in number of automobiles in India during recent years the demand of tyres as original equipment and as replacement has also increased. As every new tyre produced is destined to go to waste stream for disposal/recycling/reclamation, despite its passage through retreading process, the number of used tyres being discarded is going to increase significantly. Timely action regarding recycling of used tyres is necessary in view to solve the problem of disposal of used tyres keeping in view the increasing cost of raw material, resource constraints and environmental problems including fire and health hazards associated with the stockpiles of the used tyres. The world generates about 1.5 billion waste tyres annually, 40 percent of them in emerging markets such as China, India, South America, Southeast Asia, South Africa and Eastern Europe. All Pyrolysis plant is renewable energy generation system. Pyrolysis plants are designed to generate quality fuel from polymer waste. Pyrolysis has several advantages over other alternative tyre recycling methods. No toxic substances are emitted, and various commercial applications for all of the products obtained are possible. 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 is more economical compared to carbon black produced primarily from petroleum and is more price efficient to be used as an ingredient in the various industries. The profitability of a scrap tyre pyrolysis plant is, of course, process specific. The larger the plant capacity, the higher is the profitability. There is a very good scope and market potential for this product and new entrepreneurs should venture into this field. Cost Estimation: Capacity : Product Carbon Black 10500 MT/Annum, Fuel Oil 1200 MT/Annum Steel Wire 360 MT/Annum)
Plant capacity: -Plant & machinery: 266 Lakhs
Working capital: -T.C.I: Cost of Project : 374 Lakhs
Return: 41.00%Break even: 46.00%
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GOOD PROSPECTS IN WASTE TYRE PYROLYSIS - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities

With the phenomenal increase in number of automobiles in India during recent years the demand of tyres as original equipment and as replacement has also increased. As every new tyre produced is destined to go to waste stream for disposal or recycling or reclamation, despite its passage through retreading process, the number of used tyres being discarded is going to increase significantly. However, as the waste tire can be comprehensive utilization, most of them are become the industry waste. This phenomena is not only a kind of wasting massive available resources, but also caused the black pollution. Therefore, it influenced our life quality seriously, and became a big problem on the environmental protection. The developed countries take the waste tire regeneration seriously and all passed the Legislation and established corresponding organization to give fiscal subsidy or provide the tax-free preferential benefit, and so on in order to give fully support to the regeneration of the waste tire. Nowadays, with highly development of the rubber industry and automobile industry in our country, the enormous waste tire, scraped rubber production and its waste corner material increased rapidly. Since the rubber is not easy to purify, also with the increase of the waste rubber production, it has been the big barrier for the environment protection and intensified year by year. At present, the discarded tires, waste rubber are rich in resources all over the country. The world generates about 1.5 billion waste tyres annually, 40 percent of them in emerging markets such as China, India, South America, Southeast Asia, South Africa and Eastern Europe. In India, all new vehicles have radial tyres, so now there are piles of radial tyres here. Analysis indicates that 0.6 Million Tons of tyres scrap is generated in the country annually. It is commonly accepted in the tyre industry that about one tyre per person per year is discarded. Since there is no industry group or governmental agency that monitors tyre disposal in the country, the best estimates that can be made are based on tyre production. So supply situation of scrap tyres is only going to improve in years to come as a result of growing vehicle population in India. Mandatory scrapping of all ELV (End of Life Vehicles), in metros by 2010 to 11 and across India by 2012-13 is also likely to ensure large scale availability of scrap tyres at select locations there by encouraging organized players. The management of scrap tyres has become a growing problem in recent years. Scrap tyres represent one of several special wastes that are difficult for municipalities to handle. Whole tyres are difficult to landfill because they tend to float to the surface. These stockpiles are also direct loss of energy and resources in addition to fire & health hazard and other environmental issues. The main constituent of a tyre is rubber and the largest single application of rubber is vehicle tyres. Also the requirement of tyre is directly related to growth of automobile. The production of automobiles is forecast to continue to rise and is indicative of buoyant economic conditions for tyre industry, but at the same time guarantee and annual discarded scrap tyre volume growing at the same rate as new tyre manufacture. Waste represents a threat to the environment and human health if not handled or disposed of properly. According to this hierarchy, the priority of any country should be to extract the maximum practical benefits from products and prevent and minimize the waste that is generated. Thus, strategies for waste disposal should focus on waste prevention and minimization through the 3 Rs Reduce, Reuse and Recycle. Gasification/Pyrolysis is two related forms of thermal treatment where Waste materials are heated to high temperatures with limited oxygen availability. Waste Tyre Pyrolysis: Waste tyre pyrolysis renewable technology has set 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 an unique technology which can change the energy market scenario in a big way. The history of tyre pyrolysis projects to date indicates that the problems blocking them have been technical and economic. These include the problems of upgrading the carbon black by product while keeping down the operating cost of the process and the capital cost of the plant. Recently, there has been a technical advance in char upgrading which have helped tyre pyrolysis economically feasible. 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 (40% to 45%), carbon black (30% to 35%), steel wires (10% to 15%), and gas (10% to 12%). The main oil product produced is wide used for industrial and commercial purposes. The oil has 40% to 45% of the amount of recycled scrap tyres, which will be carried with licensed tanker trucks. 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. Tyres should be utilized to minimize environmental impact and maximize conservation of natural resources. A small unit for tyre pyrolysis can cost from Rs 4 Crores to Rs 5.0 Crores depending on the capacity of the unit. This capital cost of investment will increase as the capacity of the unit increases. The management of scrap tyres has become a growing problem in recent years. But the pyrolysis technology has a great potential for using a major portion of scrap tyres generated each year, and actually reducing the tyre stockpiles that is in other words to convert waste stream of tyres into marketable products. Waste tyre pyrolysis has indeed identified existing and potential source reduction and utilization methods which will be effective in solving the tyre problem in the coming years.
Plant capacity: 3000 MT Waste Tyre/AnnumPlant & machinery: 266 Lakhs
Working capital: -T.C.I: Cost of Project : 374 Lakhs
Return: 41.00%Break even: 46.00%
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Plastic Pyrolysis Waste Plastic to Oil Conversion

Plastics have become an indispensable part in today’s world. Due to their light weight, durability, energy efficiency, coupled with faster rate of production and design flexibility, these plastics are employed in entire gamut of industrial and domestic areas. Plastics are produced from petroleum derivates and are composed primarily of hydrocarbons but also contain additives such as antioxidants, colorants and other stabilizers. Disposal of the waste plastics poses a great hazard to the environment and effective method has not been implemented. Plastics are non-biodegradable polymers mostly containing carbon, hydrogen, and few other elements like nitrogen. Pyrolysis is the chemical decomposition of organic substances by heating the word is originally coined from the Greek-derived elements pyro "fire" and lysys "decomposition". Pyrolysis technology is thermal degradation process in the absence of oxygen. Plastic waste is treated in a cylindrical reactor at temperature of 300ºC – 350ºC. Increasing industrialization and motorization has lead to a significant rise in demand of petroleum products. As these are the nonrenewable resources it is difficult to predict availability of these resources in future, resulting uncertainty in its supply and price and is impacting growing economies like India. Many alternate fuels like Alcohols, Biodiesel, LPG, CNG etc have been already commercialized in the transport sector. In this context, pyrolysis of solid waste is currently receiving renewed interest. Plastic to oil (fuel) conversion technology has gained prominence primarily due to two factors: forming a reliable source of alternative energy from an abundant feedstock having negligible economic value and an eco-friendly disposal of non-recycled plastics. As a whole there is a good scope for new entrepreneur to invest in this business.
Plant capacity: Pyrolysis Oil: 10 MT/Day Carbon (by product) :3 MT/Day Gas (by product) : 2 MT/DayPlant & machinery: Rs 118 lakhs
Working capital: -T.C.I: Cost of Project: Rs 446 lakhs
Return: 26.00%Break even: 63.00%
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Plastic Waste Pyrolysis (Plastic to Oil Conversion)

Pyrolysis is the chemical decomposition of organic substances by heating the word is originally coined from the Greek-derived elements pyro "fire" and lysys "decomposition". Pyrolysis is usually the first chemical reaction that occurs in the burning of many solid organic fuels, cloth, like wood, and paper, and also of some kinds of plastic. Anhydrous Pyrolysis process can also be used to produce liquid fuel similar to diesel from plastic waste. Increasing industrialization and motorization has lead to a significant rise in demand of petroleum products. As these are the nonrenewable resources it is difficult to predict availability of these resources in future, resulting uncertainty in its supply and price and is impacting growing economies like India. Many alternate fuels like Alcohols, Biodiesel, LPG, CNG etc have been already commercialized in the transport sector. Recent developments in recycled plastic and plastic waste to oil market indicate that policymakers and energy industry players in various regions, particularly in North America and Europe, are focusing on the commercialization of the technology. As a whole entrepreneur can venture in this field will be successful.
Plant capacity: Pyrolysis Oil: 10 MT/Day Carbon (by product): 3.33 MT/Day Gas (by product): 2 MT/DayPlant & machinery: Rs 197 lakhs
Working capital: -T.C.I: Cost of Project : Rs 512 lakhs
Return: 26.00%Break even: 58.00%
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Plastic Pyrolysis (Waste Plastic to Oil Conversion)

During pyrolysis, plastic polymers are thermally degraded by heating them in the absence of oxygen. The main products of the pyrolysis process are liquid and gaseous, producing only a small amount of solid. The pyrolysis process is one of the most promising technologies in the conversion of waste plastics into high quality oil. The quantity and quality of the pyrolysis products depend on the waste plastics composition and the process parameters (temperature, residence time, catalyst, etc.) Waste plastic pyrolysis in liquid fuel (gasoline, diesel oil, etc.) or chemical raw materials not only can effectively solve the problem of white pollution, but also can alleviate the energy shortage to a certain extent. Recycling of waste plastics is expected to become the most effective way. Waste plastics’ recycling, regenerating, and utilizing have become a hot spot of research and gradually formed a new industry. Plastic has created a worldwide epidemic of increased waste disposal issues in key economies and developing countries. Thus, the implementation of stringent regulations has compelled market players in the recycled plastic and plastic waste to oil market to devise environmental-friendly strategies to convert plastic waste into useful fuel. The global plastic waste to oil market is expected to increase from ~US$ 45 Mn in 2019 to ~US$ 100 Mn by 2027. Plastic waste to oil can be defined as a technology that is used to convert non-recycled plastic into synthetic crude oil and other value-added petroleum products such as diesel, gasoline, naphtha, and fuel oil. This is an advanced waste conversion technology that is considered complementary to the existing plastic recycling technology. Plastic waste to oil technology has high potential, as landfill-bound plastics can be used as a resource to develop a valuable alternative fuel source. Entrepreneurs who invest in this project will be successful. Few Indian major players are as under Chevron Phillips Chemicals India Pvt. Ltd. Dream Green Petro-Chem Pvt. Ltd. M K Aromatics Ltd.
Plant capacity: Pyrolysis Oil: 5 MT / Day Carbon (by product): 1.67 MT / Day Gas (by product): 1 MT / DayPlant & machinery: Rs 92 lakhs
Working capital: -T.C.I: Cost of Project : Rs 312 lakhs
Return: 27.00%Break even: 58.00%
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