Pyrocrat Systems is a waste management company, founded by Suhas Dixit, based in Navi Mumbai India that manufactures machinery for pyrolysis plant. This presentation aims at providing a detailed review of pyrolysis process, pyrolysis oil specifications, and how pyrolysis technology can be helpful to protect the environment from improper plastic waste management.

1. Plastic Pollution
Tire Pollution?
Solution:
Reduce, Reuse, Recycle, Pyrolyse

2. Leaders in Indian Pyrolysis Plants
Manufacturer of State- of- Art Waste Plastic and Tire Pyrolysis Plants
Turnkey Supplier
machinery design >> fabrication >> installation & commissioning >> technology transfer and training
Leaders in Indian Pyrolysis Plants

3. » Leading and only manufacturer of
Continuous Type Pyrolysis Plants in
India
» Technology designed by experts in
Pyrolysis
About
» Environment friendly technology
» Proven & Commercially viable
process
» Experienced in turnkey projects -
Since 1998

4. Innovative thermo-catalytic
de-polymerisation process
Designed to generateDesigned to generate
Quality Fuel from
polymer waste

5. What is Pyrolysis oil?
» Pyrolysis oil is a Hydrocarbon
liquid
» Pyrolysis oil is generated by
de-polymerisation of plastic waste
» Applications:» Applications:
In electric generators, boilers,
diesel pumps, furnaces, hot water
generators, hot air generators,
thermic fluid heater etc.

6. Why Pyrolysis Plant?
» Increase in fuel demand
» Fuel Prices continuously increasing
» World’s fossil fuel stocks expected to last another» World’s fossil fuel stocks expected to last another
80-120 years only
» Pollution control:
Converting waste plastic/tyre into fuel & charcoal

7. Opening door to commercialization
» We have successfully developed a process
& catalyst which
– Produces industrial diesel grade fuel: Much
superior to furnace oil grade fuel
– Reduces De-polymerisation temperature– Reduces De-polymerisation temperature
from 600OC to 375-425OC
– Reduces reaction time from 90mins to 15-
45mins
– Offers more than 35% of energy savings
– Follows all Health, Safety and Emission
norms

8. Pyrolysis Reaction
Heat +
Catalyst
C-50,000 to C-2,00,000 C-1 to C-4 & C-5 to C-23
• Long Chain Polymer
– Waste Plastic
– Waste Tyre/rubber
– Crude Oil Sludge
• Short Chain Polymer
– Hydrocarbon Gas
– Pyrolysis oil
– Carbon Black
C-50,000 to C-2,00,000 C-1 to C-4 & C-5 to C-23

9. Raw Materials
- No need for segregation
- No need for cleaning
- Tolerance: 5% of dust + 5% moisture!
PVC+PET should be less than 5%
Waste Plastic
Electronic scrap
Mixed plastic (HDPE, LDPE, PE, PP,Mixed plastic (HDPE, LDPE, PE, PP,
Nylon, Teflon, PS, ABS, FRP)
Multi Layered Plastic
Waste Tyres
Rubber
Plastic or rubber parts from
vehicles
Crude Oil Sludge etc.

10. Plastic Raw Material
Waste plastic from
Waste Paper Mill

11. Finished Products
Tire Pyrolysis
Output
Oil
charcoal
Plastic Pyrolysis
Output
Oil
charcoal charcoal
Gas
charcoal
Gas
5 to 8 %
Carbon Black
70 to 90 %
Pyrolysis Oil
30 to 35 %
Carbon Black
40 to 45 %
Pyrolysis Oil

12. Pyrolysis oil Specifications
» From Tyre:
– Flash Point: 40 degree C
– Pour Point: -21 degree C
– Calorific Value: 10,150
From Plastic:» From Plastic:
– Flash Point: 60 degree C
– Pour Point: -4 degree C
– Calorific Value: 10,000

13. Charcoal Specifications & Applications
Specifications
Analysis
Method
Charcoal from Tyre
Carbon black grades
HAF(N330) SRF(N754)
Iodine Adsorption Number, mg/g ASTM D-1510 176 82 24
DBP Absorption, cm3/100g ASTM D-2414 78 92-102 50-65
CTAB Surface Area, m2 /g ASTM D-3765 68 74-90 23-39
pH – Value ASTM D-1512 9 7-9 7-10
Applications: Charcoal soil enrichment, Solid fuel, Paint
industry, ink industry, filler in plastic recycling, for
manufacturing high value products like activated charcoal etc.
pH – Value ASTM D-1512 9 7-9 7-10
Heating Loss, % max ASTM D-1509 1.5 2.5 1.5
Ash Content, % max ASTM D-1506 10 0.5 0.5
Average Particle Size, nm
MICROSCOPE
ELECTRONIQUE
300 mesh

14. Pyrolysis Process Flow Chart
Collection of Plastic waste
Cutting & Shredding
Heating + CatalysisHeating + Catalysis
De-Polymerisation
Pyrolysis oil + Carbon Black + Gas
Distillation and Purification
Petrol, Kerosene, Diesel

15. 5TPD Pyrolysis plant: Isometric View

16. 5TPD Pyrolysis plant: Isometric View

17. Land, Building &
Power requirements
Plant
Capacity
(TPD)
Power
Requirement
(BHP)
Land Area
(Square Feet)
Roof
Height
(m)
Built- up
Factory
shade Area
(Sq ft)
2 45 1,200 8 200
5 100 1,800 8 400
10 175 2,200 10 65010 175 2,200 10 650

18. Emission Under Control
Scrubbing system installed in plant to
ensure:
1. No SOx or NOx emission
2. Process designed to destroy dioxin
and furans if generated (not proven
that pyrolysis plant generates there
pollutants but still we have processpollutants but still we have process
to control this pollution
3. FSD installed
4. Scrubbing of flue gases to ensure no
particulate matter emission and
reducing the temperature of flue
gases to room temperature

19. Pyrolysis project highlights
» Raw Material: Readily available
» Payback period: 1.3 to 2.2 Years (depending on
capacity & type of RMcapacity & type of RM
» Plant is ‘energy self sufficient’
» Ready Buyers: Almost nil marketing efforts
» Perfect solution for waste plastic, rubber & tyre
management.

20. HSE:
» Airlock feeding
» Low pressure operation (300mmWC)
» Carbon removal by screw (closed system)
» No Direct heating» No Direct heating
» Certified firing systems
» Scrubbing system – no SPM, Chemical or thermal
emissions exceeding limits
» Vapour line designs

21. Efficiency and technology
» Produces industrial diesel grade fuel: Much
superior to FO grade
» Reduced reaction temperature from 600OC to 375-
425OC
» Reduced reaction time from 90mins to 15-45mins
» Offers more than 35% of energy savings.» Offers more than 35% of energy savings.
» Excess gas storage, Energy recovery
» No Heat-cool cycles of reactor, reactor MOC:
SS304/321 reactors
» Not more than 500Kg in reactor at any given time
» Pressure safety release system attached to reactor

22. Ease of operation and maintenance
» Ease of cleaning without dismantling
» No manual handling of carbon black
» No heating and cooling cycles» No heating and cooling cycles
» Automated firing system

23. Customer Service
» We provide detailed operational
manuals, drawings, troubleshooting
guidelines, maintenance manuals to
ensure smooth and independent plantensure smooth and independent plant
operation
» Free service in case of manufacturing
defect
» Chargeable service in case of
operational or preventive maintenance

24. Warranty
– 5 years from the date of
supply against manufacturing
defect
Staffing
– Will supply all necessary
skilled/unskilled workers in
case intimated about 4
months in advance

25. Global Co-operation
» Flexibility and adaptation to suit local needs
across the globe
» Confidentiality
– Non-Disclosure Agreement

26. Why ?
» Experience of establishing 22 Pyrolysis plants, we propose to establish 150
pyrolysis plants around the world by 2015. (Photos)
» Pioneer & Leaders in manufacturing, supplying and installing Indian pyrolysis
plants
» Timely delivery of machinery and quick instillation» Timely delivery of machinery and quick instillation
» Proven and time tested technology
» Purest quality of pyrolysis oil comparable to industrial diesel: Selling price
comparable to industrial diesel LDO (light diesel oil)
» Reduction in reaction temperature and reaction time by catalytic pyrolysis:
increased profitability

27. » Environment friendly processes and extensive use of
green technology.
» Safe: No charcoal leakage, no smell, no hazardous emission,
no health hazards to factory workers
» Raw material flexibility: both plastic and tires can be used.
» Continuous process: added safety and profitability
» Automated process: No manual handling of charcoal or intermediate products, reduction in
Why ?
» Automated process: No manual handling of charcoal or intermediate products, reduction in
manpower required
» Complete turnkey solution: machinery manufacturing, supplying, installation, commissioning & 1
week to 1 month on site training
» Energy self sufficient processes: no external fuel required for heating
» Three layers of safety to prevent incidences of fire. Follows all the emission norms specified by
Pollution Control Board.

28. What’s Your Message?
J-103, 1st Floor, Tower No. 7, Railway Station Commercial Complex,
Sector 1A, C.B.D. Belapur, Navi Mumbai, Maharashtra State, India. PIN: 400 614.
info@pyrolysisplant.com | www.PyrolysisPlant.com | +91-22-275-990-10/11/12