Plastic and Tire Pyrolysis Plant Manufacturers - Pyrocrat Systems LLP


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Pyrolysis plant is an industry that converts waste plastic & tires into Pyrolysis Oil, Carbon Black & Hydrocarbon Gas. End products are used as industrial fuels for producing heat, steam or electricity. Pyrolysis plant is also known as: pyrolysis unit, plastic to fuel industry, tire to fuel industry, plastic and tire recycling unit etc.

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Plastic and Tire Pyrolysis Plant Manufacturers - Pyrocrat Systems LLP

  1. 1. ? Plastic Pollution Tire Pollution Solution: Reduce, Reuse, Recycle, Pyrolyse
  2. 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
  3. 3. About » Leading and only manufacturer of Continuous Type Pyrolysis Plants in India » Technology designed by experts in Pyrolysis » Environment friendly technology » Proven & Commercially viable process » Experienced in turnkey projects Since 1998
  4. 4. Innovative thermo-catalytic de-polymerisation process Designed to generate Quality Fuel from polymer waste
  5. 5. What is Pyrolysis oil? » Pyrolysis oil is a Hydrocarbon liquid » Pyrolysis oil is generated by de-polymerisation of plastic waste » Applications: In electric generators, boilers, diesel pumps, furnaces, hot water generators, hot air generators, thermic fluid heater etc.
  6. 6. Why Pyrolysis Plant? » Increase in fuel demand » Fuel Prices continuously increasing » World’s fossil fuel stocks expected to last another 80-120 years only » Pollution control: Converting waste plastic/tyre into fuel & charcoal
  7. 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 from 600OC to 375-425OC – Reduces reaction time from 90mins to 1545mins – Offers more than 35% of energy savings – Follows all Health, Safety and Emission norms
  8. 8. Pyrolysis Reaction Heat + Catalyst C-50,000 to C-2,00,000 • Long Chain Polymer – Waste Plastic – Waste Tyre/rubber – Crude Oil Sludge C-1 to C-4 & C-5 to C-23 • Short Chain Polymer – Hydrocarbon Gas – Pyrolysis oil – Carbon Black
  9. 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, Nylon, Teflon, PS, ABS, FRP) Multi Layered Plastic Waste Tyres Rubber Plastic or rubber parts from vehicles Crude Oil Sludge etc.
  10. 10. Plastic Raw Material Waste plastic from Waste Paper Mill
  11. 11. Finished Products Plastic Pyrolysis Output Tire Pyrolysis Output Oil charcoal charcoal Gas 5 to 8 % Carbon Black Oil Gas 70 to 90 % Pyrolysis Oil 30 to 35 % Carbon Black 40 to 45 % Pyrolysis Oil
  12. 12. Pyrolysis oil Specifications » From Tyre: – Flash Point: 40 degree C – Pour Point: -21 degree C – Calorific Value: 10,150 » From Plastic: – Flash Point: 60 degree C – Pour Point: -4 degree C – Calorific Value: 10,000
  13. 13. Charcoal Specifications & Applications Analysis Method Specifications Carbon black grades Charcoal from Tyre 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 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 Applications: Charcoal soil enrichment, Solid fuel, Paint industry, ink industry, filler in plastic recycling, for manufacturing high value products like activated charcoal etc.
  14. 14. Pyrolysis Process Flow Chart Collection of Plastic waste Cutting & Shredding Heating + Catalysis De-Polymerisation Pyrolysis oil + Carbon Black + Gas Distillation and Purification Petrol, Kerosene, Diesel
  15. 15. 5TPD Pyrolysis plant: Isometric View
  16. 16. 5TPD Pyrolysis plant: Isometric View
  17. 17. Land, Building & Power requirements Plant Power Capacity Requirement (TPD) (BHP) Land Area (Square Feet) 2 5 10 1,200 1,800 2,200 45 100 175 Built- up Roof Factory Height shade Area (m) (Sq ft) 8 200 8 400 10 650
  18. 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 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. 19. Pyrolysis project highlights » Raw Material: Readily available » Payback period: 1.3 to 2.2 Years (depending on capacity & type of RM » Plant is ‘energy self sufficient’ » Ready Buyers: Almost nil marketing efforts » Perfect solution for waste plastic, rubber & tyre management.
  20. 20. HSE: » » » » » » Airlock feeding Low pressure operation (300mmWC) Carbon removal by screw (closed system) No Direct heating Certified firing systems Scrubbing system – no SPM, Chemical or thermal emissions exceeding limits » Vapour line designs
  21. 21. Efficiency and technology » Produces industrial diesel grade fuel: Much superior to FO grade » Reduced reaction temperature from 600OC to 375425OC » Reduced reaction time from 90mins to 15-45mins » 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. 22. Ease of operation and maintenance » Ease of cleaning without dismantling » No manual handling of carbon black » No heating and cooling cycles » Automated firing system
  23. 23. Customer Service » We provide detailed operational manuals, drawings, troubleshooting guidelines, maintenance manuals to ensure smooth and independent plant operation » Free service in case of manufacturing defect » Chargeable service in case of operational or preventive maintenance
  24. 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. 25. Global Co-operation » Flexibility and adaptation to suit local needs across the globe » Confidentiality – Non-Disclosure Agreement
  26. 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 » 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. 27. Why » » » » » » » » ? 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 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. 28. 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. | | +91-22-275-990-10/11/12 What’s Your Message?