Manufacturer Of Waste Tyre Recycling Plant

Project Report

REUSE
REDUCE
RECYCLE
 Welcome to FAB INDIA

Fab India Is a Pioneer in the Field Of Designing, Developing and Quality Manufacturing with
more than 20 years experience situated at Ahmedabad, Gujarat. Fab India is professional and
high-tech companies to manufacture waste tyre recycling plant with a wide range (5 ton, 7.5
ton, 10 ton and 12 ton), good quality, reasonable prices, all the safety precautions and stylish
designs, 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 is a Dominant firm involved in manufacturing,
supplying and installation of Pyrolysis Equipment and Waste Tyre Recycling Plant. We also have
our 3-manufacturing unit, which has been operating since 1993 regarding pharmaceutical
machinery , chemicals plant, minerals plant, food processing plant, textile plant 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 hydrocarbon gas. Our Eco-
friendly technology is 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/
month) 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 this
industry. His tremendous knowledge, leadership, expertise skills and experience has enabled us
to export our products to all over India.

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Fab India’s workshop

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 Pyrolysis process
• Pyrolysis is the chemical decomposition of organic materials by heating in the absence of
oxygen or any other reagents, except possibly steam.
• Pyrolysis can be used to reprocess the tyres into fuel oil, fuel gas, solid residue (steel wire)
and carbon black.
• The waste tyres are mainly composed of long chain of C-H molecules.
• Under normal process conditions the heat transfer will be done by radiation.
• The technology of pyrolysis, cracking, and monomerisation of used tyres is always a hot topic.

 Tyre pyrolysis

End-of-life tyres contain a lot of chemical bound energy.

As a result of pyrolysis of waste tyres one obtains: high-energy gas, Pyrolysis oils, carbon black
and steel wire. The ratios of the first three products depend on process conditions, mainly on
temperature.

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

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 Variety of polymer waste material is suitable as a raw material.
Given below is the list of suitable raw materials for pyrolysis:
 Waste tyres
 Rubber or rubber parts from vehicles
 Electronic scrap
 Mixed (HDPE, LDPE, PE, PP, Nylon, Teflon, PS,ABS,FRP etc)
 Multi layered
 Plastic disposable bottle
• The choice of feedstock and process (mainly operating temperature) can affect the value of
the finished products.
 Input-output ratio of waste tyre
Type of Material Total Quantity Finish quantity
-550 to 600 liter of Pyrolysis oil
Nylon scrap tyres 1000 kgs -50 to 80 kg of Hydrocarbon Gas
-300 to 350 kg of Carbon Black
-400 to 450 of Pyrolysis oil
-50 to 80 kg of Hydrocarbon Gas
Radial scrap tyres 1000 kgs
-300 to 350 kg of Carbon Black
-150 to 200 kgs of Mild steel tyre scrap

 Yield of pyrolysis process:

H Pyrolysis oil (Fuel oil – 40 to 45%)
• 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 in fire chamber.
Pyrolysis oil has flash Point between 60 to 93.3 °C.
• Purest quality of pyrolysis oil comparable to industrial diesel: selling price comparable to
industrial diesel LDO( light diesel oil)
H Carbon Black(30 to 35%)
• 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.
H Steel wire(15 to 20%)
• 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
H Hydrocarbon Gas(5 to 8%)
• 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

H Advantages of pyrolysis plants

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

H Benefits of pyrolysis plant

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

H Basic 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 10 to 12 hours.
• Pyrolysis of tyre is done in the absence of oxygen.
• Scrubbing of pyrolysis oil, hydrocarbon gases and fuel gases to prevent pollution.

H Pyrolysis plant needs following machinery & equipment:

• Raw material handing section. • Pyrolysis oil storage system.
• Pyrolysis reactor • Cooling tower.
• Hydraulic cutter. • Control panel and alarm systems.
• Hydraulic auto feeder. • Equipment line in commercial pyrolysis
• Condensation system. plants is further modified to suite
• Scrubbing system. customer’s requirements.
• Hydrocarbon gas cleaning
& storage system.

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Shell Plate (B.Q. Plate SA 516 Gr.70) Test Report

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 Flowchart for pyrolysis process

Waste tyre (Nylon/Radial tyre)

Pyrolysis process
Pyrolysis plant

Pyrosis oil Carbon black Steel wire

Hydrocarbon gas
(Fuel oil-LDO) (charcoal) with
small particle of
steel wire

Pyrolysis Oil
Storage System Storage Recycle burning
Carbon black Unit

Deliver to Storage Compressed

refinery unit Scrubber Unit

Pulverizer
system Transfer to
scrap dealer Chimney

Magnate & Sleeve Collect

Carbon coal Plant Sale to market

Bracketing Machine

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 Technical detail of 12 ton PYROLYSIS PLANT

Sr No Item Contraction Description

16 MM BQ Plate Capsule 6.6 Meter(l) x 2.8 Meter(w),Plate
1 Main Reactor-12 ton
Type(FIRC-12) Thickness-16 MM ,
5 MM MS Plate OR C
2 Pipe condenser Pipe 24 Nos , diameter-6 inch
Class Pipe -5MM MS
700 MM x 1550 MM ,Cera
3 Insulation tank 5 MM MS Plate wool(1260 °C) insulation covered 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 1470 x 3000 (5.0 KL ) 2 Nos.

C Class Pipe -5 MM MS (15'X8" & 12'X16" ) [ 15 Feet ] ,
7 Water coolant pipe
Pipe jacketed pipe
8 Scrubeer Reactors C Class Pipe -5MM MS Top Pipe 12" X 10 Feet

9 Scrubber Fan Pipe C Class Pipe -5MM MS 12" X 10 Feet

Scrubber Coolent
10 C Class Pipe -5MM MS 12" X 15 Feet
Pipe
1000 MM x 2800 MM with coolant
11 Scrubber Tank 5 MM MS Plate
pipe
12 Dust Blower 5 MM MS Plate 5 HP Blower with Motor

13 Cooling blower 5 MM MS Plate 5 HP 1440 RPM ABB MOTOR

5"Gear Box With 5 HP ABB Motor
14 Hoist 5MM MS Fabricated
With Wire Rop 80 Feet(L), 10MM(T)
2 Tons chain block with 10 Feet chain
15 Chain block 2 Tons Chain block
for reactor door
Total motor Controller, temp indicator
Reactor Penal board with
16 Penal board and controller with hooter penal
7.5 HP Motor
board
Submersible Water 5 HP 3 Phase Electric Motor for cold
17 Pump Atlas brand
pump water supply in condenser
3 HP 3 Phase ABB Motor for oil
18 Gear pump Pump Atlas brand
transfer

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 Technical detail of 12 ton PYROLYSIS PLANT

Sr No Item Contraction Description

3 HP 3 Phase ABB Motor for scrubber
19 Mud pump Pump Atlas brand
systems
C Class Pipe -5MM 12"
20 Chimney 20 Feet-2 Nos for chimney
MS
0.5 Hp Motor 3 Phase for fire
21 Gas Blower 3 Nos Gas blower 0.5 HP
chamber
22 gas burner C Class Pipe -5MM MS 100x450 MM

23 Cooling tower Capacity 80 TR 3 HP 2880 RPM Motor

Hardware for reactor pipe and pipe
24 Hardware As per annexure I
fitting
With cerawool 1260 Temp 25 MM
25 Reactor cover Reactor cover insulation
Two layer
26 Electric Motor Standard make As per annexure II

27 Foundation As per drawing Price not including in basic Price

28 Reactor Gear box Shricon Brand 180 Center 10 HP Helical Gear

500 Nos Fire Brick
Fire Brick &
29 and castable cement - For fire system
Castable cement
4+4 bags
Hydraulic
5 MM Plate and 100 MM 5 HP Hydraulic Auto Feeder, works
30 Auto feeder
Channel with 40 tons hydraulic pressure
[ Extra Price ]
Hydraulic cutter 5 HP Hydraulic Auto Feeder, works
31 16MM MS PLATE
[ Extra Price ] with 40 tons hydraulic pressure
8"PIPE COVERD with
Material handing 3 Hp motor WITH 4"GEAR,18 feet
32 12"PIPE(5MM) with
screw for carbon long
cooling system

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14
FI - RC - 12 TPD Pipe
Condenser Model

3 4
3 4 5
2
5
2 6
1
6
1

70 TR
3 4
5
2
6
3 4 1
5
2
6
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 Technical Parameter
MINIMUM LAND REQUIREMENT FOR PLANT : 50' X 120'(FEET)
TOTAL LAND REQUIREMENT FOR PLANT : 90' x 120'(FEET)
Foundation drawing will be send by us

S.N Items Model Model Model

1 Equipment type FI - RF-5 FI - RC-10 FI-RC-12
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 8.5 ton 10.5 ton
5 Oil yield [40 to 45 % oil] 1.72 ton 3.8 ton 4.7 ton
6 Steel Scrap [15 to 20 %] 0.86 ton 1.7 ton 2.1 ton
7 Carbon [30 to 35 %] 1.29 ton 2.5 ton 3.1 ton
Normal ( 0.3 To Normal ( 0.3 To Normal ( 0.3 To
8 Operating pressure
0.5 Kg) 0.5 Kg) 0.5 Kg)
[Link] SA 516 [Link] SA 516 [Link] SA 516
9 Material of Reactor
Gr.70 Gr.70 Gr.70
10 Thickness of Reactor 12 mm 14 mm 16 mm
11 Rotate speed of Reactor 0.4turn/minute 0.4turn/minute 0.4turn/minute
12 Total power 20KW 25KW 33KW
13 Mode of Water cooling Circular cooling Circular cooling Circular cooling
Cooling area of
14 18 [Link] 60 [Link] 70 [Link]
condenser
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. 2.6×6.6 Mt. 2.8 × 6.6 Mt.
Intermittent Intermittent Intermittent
18 Working form
operation operation operation
19 Lend requirement 10,800 Sq Feet. 10,800 SqFeet. 10,800 SqFeet.
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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 Model and Price list

Capacity Shell Plate Coolant

Load Shell Price
Sr. Model in kilo Length thickness Condenser area
in diameter INR
No. (Ton wise) liter (MM) (MM) Nos Sq. Mtr
ton (MM) (Lac)

1 FI-RF-5 T 24 KL 4.5 2200 6000 12 32 1+1 20

2 FI-RF-7.5 T 30 KL 6.9 2200 7500 14 35 3 25

3 FI-RF-10 T 37 KL 9 2600 6600 16 39 4+1 31

FI-RC-10 T
24 Nos Pipe
4 Pipe condenser 37 KL 9 2600 6600 14 42 51
Condenser In series
(Economy Model)
24 Nos Pipe
5 FI-RC-10 T 35 KL 8 2600 6600 16 44 51
Condenser In series
FI-RC-10 T 2 horizontal,
6 37 KL 9 2600 6600 14 45 39
5th Genration 2-vertical condenser
FI-RC-10 T 4 horizontal, 2-
7 37 KL 9 2600 6600 16 48 46
7th Genration vertical condenser
24 Nos Pipe 6" 77
8 FI-RC- 12 T 43 KL 11 2800 6600 16 52
Condenser In series [Pipe]
32 Nos Pipe 6" 102
9 FI-RF- 15 T 54 KL 13 2800 7100 18 57
Condenser In series [Pipe]
Installation charge included
Extra Tax -2 % CST Against "C" Form, Transportation Extra

Extra Accessories

1 Hydraulic Auto feeder Rs 3,10,000

2 Hydraulic cutter Rs 3,25,000

3 Material handing screw Rs 1,26,000

4 Chimney Cost Extra 100 feet Rs 2,20,000

Cable and wire charge not including
5 Extra
in our price

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 Payment Terms and Condition
• Terms & Condition: Payment
• 30 % Advance & 70 % Against Delivery

H Evaluation of Expenses and gross profit

S.N Other Contingent Expenses (per month) Amount (Rs.)
1 Postage and Stationery 2,000.00
2 Telephone 5,000.00
3 Travelling and freight 15,000.00
4 Consumables 10,000.00
5 Repair and Renewals 10,000.00
6 Insurance fire and Employee 10,000.00
7 Rent NIL
Total Amount 1 Total 52,000.00
Utilities (per month)
S.N Personnel Salary (Rs.) Nos. Amount (Rs.)
1 Production Manager 25000 1 25,000.00
2 Maintenance engineer 15000 1 15,000.00
3 Semi-skilled workers 8000 6 48,000.00
4 Watchman 8000 1 8,000.00
5 Additional perquisites @ 20% 11,000.00
6 Waste Tyre 11000 kg. per day x 22days x Rs 11per Kg 26,62,000.00
7 Coal/wood 2000 kg. per day x 22days x Rs 6/kg 2,37,600.00
8 Power 45HP x 0.75 x 24hours x 22 days x Rs 6 46,000.00
9 Water 7000.00
Total Amount 2 Total Amount 30,59,600.00
Total Recurring Expenditure (per month) Rs. Total Amount 1 + Amount 2 31,11,600.00
Turnover per Monthly Presented Per Month
1 By selling Oil 4730 Ltrs*22 days*Rs32/Ltr. 42% to 45% 33,29,920.00
2 By selling steel scrap 2200kg*22days*Rs12/kg 15 %to 20% 5,80,800.00
3 By selling Carbon 3190Kg *25days*Rs 1.5 /kg 30%to 35% 1,05,270.00
4 Gas Around Recycling 5% to 10% Nil
Turnover per Monthly 40,15,990.00
Total Recurring Expenditure (per Monthly) Rs. 31,11,600.00
Profit Gross Per Monthly Monthly Profit 9,04,390.00
Gross Annually Profit 1,08,52,680.00
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12 Tons Pyrolysis Plant Total Investment in One Plant [without land]

Approximate
S.N Details
Price
1 12 Tons Machine Cost Without tax 52,00,000-00*
2 Transportation cost Trailer/ trucks 1,50,000-00
3 Shed fabrication works [open shed] 50 Feet x 100 Feet 5,00,000-00
4 Oil Storage Tank 25000 Ltr. 1,50,000-00
5 Foundation cost only Machine As per dwg 3,50,000-00
6 D.G. Generation set [ 40 KW] Standard 3,50,000-00
10 x 10 Feet x 2
7 Site Office [ medium ] 3,25,000-00
Room
8 Pollution certificate 50,000-00
Electric Connection/Cable/Wiring Connection
9 25,000-00
charge
10 Other Expenses 1,00,000-00
11 Land Investment xxxxxxxxxx
12 Raw Material Expenses xxxxxxxxxx

Total Investment of 12 Tons Plant 72,00,000.00

"Your Challenge is our Progress"

Works: Plot No.3/4, Khodiyar Estate, Inside Shakriba Estate, Phase – IV,
Vatva G.I.D.C, Ahmedabad-382 445.
Soham Patel: +91 97250 12741, Pratul Patel: +91 97250 12747
Other Contacts :+91 97250 12744 /+91 97250 12746.
Office No : +91 8980014620/21. Tel No : +91 79 40301472.
Email Id: info@[Link], info@[Link], fabindia2@[Link]
Skype ID: FABINDIA3133,
Web Site: [Link]