OVERVIEW

Pyro = Heat. Lysis = Break Down. Pyrolysis Is Chemical Reaction. This Reaction Involves Molecular Breakdown Of Larger Molecules Into Smaller Molecules In Presence Of Heat. Pyrolysis Is Also Known As Thermal Cracking,, Thermolysis, Depolymerization, Etc. At Any Given Temperature The Molecule Is In Vibrating Stage. This Is Called Molecular Vibration. During Pyrolysis The Object’s Molecules Are Subjected To Very High Temperatures Leading To Very High Molecular Vibrations. At These High Molecular Vibrations, Every Molecule In The Object Is Stretched And Shaken To Such An Extent That Molecules Starts Breaking Down Into Smaller Molecules. This Is Pyrolysis. Simplest Example Of Pyrolysis Is Food Cooking. When You Cook Food The Temperature Of Food Increases Leading To Higher Molecular Vibrations And Breakdown Of Larger Complex Molecules Into Smaller And Simple Molecules. After Cooking Larger Food Molecules Are Pyrolyzed Into Smaller In Simpler Molecules Which Are Easy To Digest. This Technology Is A Well-proven, Well-demonstrated Commercially Viable Technology, Which Is Currently Utilized In Industrial Plants Worldwide.

We, FABHIND Manufacture The Continuous Waste Tyre Recycling Project, Semi Continuous Plant And Batch Type Tyre Pyrolysis Plant Equipment That Can Process The Waste Tires And Get The Crude Oil. At The Same Time It Also Can Get The Carbon Black, Flammable Gas And So On. It Can Not Only Solve The Problem Of The Environmental Pollution, But Also The Question Of The Shortage Of The Energy. Then It Can Help Us Create The Big Economic Profit.

CONTINUOUS TYRE RECYCLING PLANT

The whole project is composed Ofthe Whole Project Is Composed Of 50 Tpd Continuous Waste Tire Pyrolysis Plant: 50 TPD Continuous Waste Tire Pyrolysis Plant.

• Raw Material Waste Tire Chips (5 To 25 Mm Steel Free Wire)
• Final Product Tyre Pyrolysis Oil, Carbon Black Powder, Pre Processed Steel Wire
• Physical Parameters
• Raw Material : Waste Tyre Chips 5 T O 25 Mm ( Steel Free Tyre) Not Suitable For Shredded Tyres
• Capacity : 50 Ton Per Day
• Status of Slag : Carbon and Flash
• Area : 3000 Square Meter
• Production
• Tyre Pyrolysis Oil : 40 % to 42 %
• Carbon Black Powder : 30 % to 33 %
• Consuming Data
• Fuel : Tyre Pyrolysis Oil , Uncondensed Gas
• Daily Input Capacity : 50 Ton Per Day
• Cooling Water (Evaporating Loss) : 1000 Liter Day
• De-dusting Water (Consumption Loss) : 2000 Liter per day

TECHNICAL SPECIFICATION

ADVANTAGES

According To The Continuous Pyrolysis Technology, The Equipment We Recommend In This Proposal Is The Fab Continuous Plant Updated Equipment Of Our Company. It’s The New Developed Process, Including Continuous Feeding System, Continuous Rotating Pyrolysis System, Continuous Slagging System, Continuous Cooling System, Smell Removal System, Continuous Tail Gas Recycling System, Continuous Smoke Cleaning System As Well As Plc Automatic Control System, Etc. The Whole Pyrolysis Process Is Running Under A Completely Sealed Environment And On Very High Automatic Control Level, No Need Manual Operation For Feeding &Slugging. The Fully Automatic And Mechanical Process Makes Sure The Working Environment Is Totally Safe And Clean.

• Our Reactor Has 360 Degree Outside Rotating System Which Allows It To Heat Proper Way So It Has Long Life,
• Spiral Flats Are Designed In To The Reactor Which Helps Running The Material By Its Inner Wall. The Raw Material Direct Contacted With The Heat Transfer Surface And Received Immediate Heat And Evenly Distributed.
• The Reactor And Feeder System Adopts Frequency Drive (VFD) To Adjust The Retention Time Of Raw Material In The Reactor According To The Pyrolysis. It Can Decompose In Minimum Time To Increase High Oil Yield.
• Reactor Can Be Loaded By Steel Wire Free Tyre Chips And It Can Also Separate The Carbon Black From Hair Steel Wires At The Time Of Carbon Discharge. It Has Hair Steel In Wires It Can Be Collected By Hair Steel Magnet Separator Machine. Hence It Will Be Collected Directly To The Carbon Bags If It Doesn’t Have Hair Steel In It.
• Gas & Oil Burner Can Be Used For Extra Flue Uncondensed Gas For Secondary Heating Process Of The Pyrolysis Reactor, Which Will Reduce Production Cost And Customer Revenue. The Flue Gas After Combustion Is Treated By Dual Wash Scrubber System As Per Environment Standards. Ii Is Using Evaporated Flue Gas For Heating Process Of Reactor, Where We Recycle Extra Heat For The Process.

SAFETY MEASURES

• The Invention Of "Special" Sealing Methods And Structures. Full Continuous Pyrolysis Process Is The Continuous Supply Of Raw Materials To The Reactor During The Pyrolysis Process Of The Reactor, And The Slugging And Prevention Of Pyrolysis Oil And Gas From Leaking Through The Feed Inlet And Slag Outlet. It Has Sealing Box At The Feeding And The Interlocking Sealing Device Of Discharging With Gas Kit And Gland Rope To Prevent Oil And Gas From Leaking During Production And Ensuring Safe Production
• It Has Dual Air Lock Valve System To Control The Pressure Of Gas During The Process, Where It Will Help To Input Raw Material Continuously.
• Carbon Black Powder Will Be Unloaded By Its Carbon Unloading Screw With Help Of Dual Air Lock System, Where It Will Connected To Output Conveying System To The Cooling Ribbon Blender. By Using Of Ribbon Blender It Can Reduce The Total Process Time.
• It Has Dual Tail Gas Treatment System. The Non-condensable Flammable Gas Produced In The Process Of Generation Can Be Deodorized To Remove The Harmful Gas With Irritating Odor. After The Initial Purification, The Non-condensable Flammable Gas Heat The Reactor As A Supplementary Heat Source. The Generated Dusty Flue Gas Passes Through The Venture System Eliminate The Harmful Gas Components And Fumes In The Flue Gas Auto Ignition Flaring At 30 Meter Height To Reach The Environmental Protection Standard.
• The Condensing Equipment Line Has Pipe Condenser Type Of Design. The Uncondensed Oil And Gas Are Taken In The Pipe Where The Water Is Taken Away From The Pipe To Exchange Heat. It Has 45 Square Meter Of Coolant Area Of Water Pool Connected To Cooling Tower For Reducing Temperature Of Recycled Water. It Has Zero Discharge Of Water.
• Fab Continuous Plant Has Micro-negative Pressure Process. The Main Advantage Is That It Can Ensure That The Pyrolysis Oil And Gas Continue To Move To The Rear Of The Production System, Preventing The Condensed Gas From Flowing Back To The Reactor, Causing Secondary Heating And Re-cracking To Achieve Energy Conservation And Improve Oil Quality.

SAFETY EVALUATION

• Leakage prevention The Equipment Adopts A Fully Enclosed Structure, And All The Hazardous Media Is Operated In The Closed System. The Welds Of The Whole Equipment Including The Reactor Are 100% Non-destructive Testing Qualified. Besides, The Equipment Is Qualified For Airtight Testing Before Delivery To Ensure There Is No Leakage In All The Flange Connections, Threaded Connections And Welds. The Pipelines And Other Joints Installed On-site Shall Also Be Airtight Tested Before Being Put Into Use.
• Real-time monitoring of pressure and temperature Reactor Has Pressure Control And Temperature Control Sensors To Indicate Accurate Pressure And Temperature Of Reactor. Fab Continuous Plant Has Installed Plc System To Prevent Unnecessary Pressure & Temperature; It Also Monitors Operating Pressure And Temperature. When It Limits The Pressure And Temperature Plc Will Anomaly Observe red And Promptly Sound And Light The Alarm.
• Detection of flammable Gas The Device Area Should Be Well Ventilated To Prevent The Explosive Limit When The Accidental Leakage Of Combustible Gas In The Device Area Is Too High. If Conditions Are Met, We Install Flammable Gas/vapor Detector In The Device Area So That The Flammable Gas Around The Device Area Can Be Monitored In Real Time To See If The Gas Concentration Is Too High.
• Fire Fighting Systems
• The Device Area Should Be Well Ventilated To Prevent The Explosive Limit When The Accidental Leakage Of Combustible Gas In The Device Area Is Too High. If Conditions Are Met, We Install Flammable Gas/vapor Detector In The Device Area So That The Flammable Gas Around The Device Area Can Be Monitored In Real Time To See If The Gas Concentration Is Too High.
• Workers Must Use Explosion-proof Tools And Wear Qualified Labor Protection Products When Working. During The Maintenance Process Reactor Pipelines, The Internal Pressure Must Be Released First, And The Medium Should Be Replaced, Then It Could Be Opened After Qualified Testing. If You Need To Carry Out Hot Or Fire Work On The Equipment, You Must Implement Safety And Technical Measures Such As Cutting Off, Isolation, Replacement, Cleaning And Ventilation, And Follow The Procedures To Complete The Worksheet.
• Operating Training & Maintenance
• Suppliers Provide Theoretical Operating Training By Qualified Engineers At Our Facility. Fab Continuous Plant Also Provides Practical Training To Owner And Their Qualified Employees At Their Running Site Location. All Personnel Should Be Trained And Qualifiedly Tested Before Starting Job.
• Supplier Provides Standard Operating Procedures Along With Its Plant
• The Parts Must Be Kept Away From The Equipment By 50 Meters With The Fire Or Welding Work. If It Is Impossible To Remove The Work Piece Or Equipment, Then The Entire Equipment Must Be Cleaned And Free From Any Oil And Flammable Materials First, And With Sufficient Fire Protection Measures And Labor Protection Conditions Can It Be Performed. .
• Backup Power & Water Supply During The Operation, The Device May Have Abnormal Temperature And Pressure Rise With Power Failure Or Water Stoppage. It Is Recommended That Users Have Power Backup ( 100Kva) And Water Sources.

FEATURES

• Continuous pyrolysis process Shredded Tyres ( 1 MM To 5 MM )go Into The Continuous Waste Tyre Pyrolysis Plant, Will Firstly Go Through A Multiple Pyrolysis Reactor System To Be Pyrolyzed Into Oil Gas. And Oil Gas Will Be Cooling Down To Liquid Oil Through The Cooling System. The Residues (Carbon Black) Will Be Pushed By Continuous Feeding Tyres To The Carbon Black Discharge System For Discharge.
• Main Features Of Fully Continuous Waste Tire Pyrolysis Plant
• Environmental-friendly
• Security
• High Profit
• High Oil Out Put
• Fully Automatic With Low LaborCost Our Continuous Waste Tyre Pyrolysis Plant Is Controlled By Plc System With Automatic Feeding And Discharge System, Which Only Need 1-2 Worker For Operating The Plc Or Computer Is Ok.
• Fully Pyrolysis For High Oil Output Our Continuous Waste Tyre Pyrolysis Plant Adopts Multiple Reactor Design Which Can Make Fully Pyrolysis Of Waste Tires, Thus To Get High Oil Output.
• Big Capacity Also Due To Continuous Feeding And Discharge System, And Unique Multiple Reactor Design, Our Fully Automatic Continuous Waste Tyre Pyrolysis Plant Can Process At Least 10 Tons Waste Tires Per Day, Up To 100 TPD
• Internal Rotating for ContinuousOperation For External Rotating System, You Have To Change The Sealing Material Every Three Days, Thus Cannot Achieve The Real Sense Of Continuous Process. But Our Continuous Waste Tyre Pyrolysis Reactor Adopts Internal Rotating Method, Which No Need To Worry About The Sealing Of The External Rotating System.
• Continuous Working Save Time and Energy
• Long Working Life During The Continuous Pyrolysis Process, Reactor Heating Is By Indirect Hot Air Heating, Which Will Not Damage Reactor So Much, Thus To Keep Long Usage Life Of The Reactors. And Since The Hard Steel Wire Already Removed From Waste Tires Before Pyrolysis Process, Thus No Damage For The Reactor.

APPLICATION

• Application of Fully Continuous Waste Tyre Pyrolysis Plant
• Waste Tyre Chips
• Fuel Oil
• Carbon Black
• Steel Wire
• Application Of Fully Continuous Waste Tyre Pyrolysis Plant
• For Our Continuous Waste Tyre Pyrolysis Plant, The Applicable Raw Materials Can Be Any Kinds Of Waste Tires, Such As Bicycle Tires, Motorcycle Tires, Car Tires, Truck Tires, Etc.
• Except The Steel Wire Extracted Out From Waste Tires In The First Stage Pretreatment Process, The Final Products From Waste Tire Pyrolysis Process Will Be Fuel Oil And Carbon Black. Application Of Fully Continuous Waste Tyre Pyrolysis Plant
• Use of Tyre Oil
• Heavy oil Burner
• - Road Contraction Machinery
• - Cement Plant
• - Brick Factory
• - Chemicals Factory
• Fuel Oil Application When The Whole Process Is Over, We Can Get End-products That Have A Wide Range Of Applications. For Example, The Pyrolysis Oil Can Be Widely Used As Fuel Oil In Industries Such As Steel And Iron And Boiler Factories, Ceramics, Power Or Chemical Industries Or Hotels, Restaurants Etc. Or Used For Generators To Get Electricity. The Carbon Black Can Be Used For Making Construction Bricks With Clay, Or Used As Fuel. The Steel Wire Can Be Sold Directly Or Recycled To Produce New Steel Products
• Use Of Carbon Block
• - Tyre Industries
• - Rubber Industries
• - Painting Ink
• - Pigment Industries
• - Chemicals Factory
• - Active Carbon
• High Capacity And Small Land Occupy Size Our Fully Continuous Waste Tyre Plastics Pyrolysis Plant Can Process At Least 40 To 50 Tons Waste Plastics Per Day, Up To 100 TPD. And Due To Integrated Design The Plant Has Small Land Occupy Size.
• Fully Pyrolysis For High Oil Output The Accurate Calculation System Is Adopted to Make Fully Pyrolysis of Waste Plastics, And Three-stage Tubular Condensing System Can Ensure The Cooling Effect Highest, Thus To Get High Oil Output.
• Fully Automatic With Low Labor Cost It Is Controlled By Plc System With Automatic Feeding And Discharge System, Which Only Need 3-4 Worker For Operating The PLC Or Computer Is Ok, Saving Labor Cost.
• Continuous Operation For Saving Time And Fuel For External Rotating System, You Have To Change The Sealing Material Every Three Days, Thus Cannot Achieve The Real Seal Of Continuous Process. But Our Continuous Waste Plastics Pyrolysis Reactor Adapts Internal Rotating Method, Which No Need To Worry About The Sealing Of The External Rotating System. In This Way, The Fully Continuous Waste Plastic Pyrolysis Plant Can Run For 24 Hours A Day Without A Stop And Needn’t To Be Cooled Before The Second Batch, Which Not Only Saves Time, But Also Saves Fuels.
• Long Working Life During The Continuous Pyrolysis Process, Reactor Is Heated By Indirect Hot Air Heating, Which Will Not Damage Reactor So Much, Thus To Keep Long Usage Life Of The Reactors

ITEM PARAMETERS

• Pyrolysis Reactor
• Reactor Rotating System 1200 Kg per hour,
• Inside Reactor Material Moving,
• Reactor Size : 2 x 24 Miter
• Direct heating System
• Sealing : Hard and Soft Sealing
• BQ Plate of 516-70 Grade
• Reactor Insulated Cover by Cera wool
• Fire Furnace Chamber
• Fire Burner – 8 Nos,
• Gas & Oil Burner – 8 Nos,
• Air Pressure Blower for Gas & Oil Burner,
• Pneumatic Valve Connected to Digital Panel Board forAutomatic Temperature Control
• Material Feeding Hopper
• Hopper Capacity
• Bottom Belt Conveyer
• Feeder VFD Drive
• 2 Tons Capacity
• VFD Feeding Systems
• Material Feeding Systems
• Conveyor with Input & Output Hopper,
• Electric Motor : 3 HP,
• Gear Box SMRS Type D , Ratio : 13:1 ,
• 3 Ply 8 MM x 500 MM (Width
• Controlling Method (Programmed Logic Control - PLC)
• Material Feeding Conveyor Belt
• Material Feeding Screw
• Heavy Screw 400 x 4000
• Reduction Gear Box
• Electric Motor 7.5 HP,
• Screw Gland Pusher
• MS Fabricated Railing Stand
• Material Loading Dual Airlock System
• Carbon Output Screw
• Heavy Screw 440 x 2000
• Reduction Gear Box NU-600
• Electric Motor 7.5 HP,
• Screw Gland Pusher,
• MS Fabricated Railing StandMS Fabricated Railing Stand
• Carbon Unloading Dual Airlock System
• Carbon Removal Jacket Screw
• Screw 16 ” with Water Jacketed
• Reduction Gear Box
• Electric Motor 5 HP,
• Gland Pusher for Screw
• Carbon Removal Pipe Screw
• Pipe Type Screw
• Electric Motor 5 HP,( Direct Pulley Drive)
• Gland Pusher for Screw
• Cycle- Carbon Storage
• Loading Capacity 4 Tons
• Temperature Meter Analogue & Digital Meter Sensors,
• Capacity 10,000 Liter,
• Capacity 10,000 Liter,
• Bottom Out Put Knife valve 8” ( Manually )
• Carbon Cooling System
• Carbon Steel Removal System
• Drum Magnetic Separator,
• Automatic Separation of Iron Impurities.
• Electric Motor 2 HP,
• Drum Consists of High Coercively Modern Anisotropic Permanent Magnets.
• Completely Enclosed Design to Avoid Dusting and Pollution.
• Bag Manually Feeding 50 KG
• Heavy Oil Buffer Chamber
• Heavy Oil Tank,
• MS Fabricated
• Heavy Oil Collecting Dual System
• Indicator Pipe with Pressure, temperature Meter and Safety Valve,
• Dual Tank System Connected to Pipe &Instruments
• Primary Tank with Heavy oil Collecting Tank – 500 Liter
• Jacketed Coolant Pipe
• Water Jacketed 16 “ Pipe
• 15 Feet Long Jacketed Pipe
• Attached Pressure and Temperature Sensor
• Water Seal Tank
• Full Water Jacketed
• Oil & Gas Output System
• CI Casting Sight Glass
• Condensation System
• Condenser 3 Nos
• Damnation 2500 x 800
• Cooling -Water Jacked
• Cooling Tower
• Water Cooling Tower- 100 TR,
• Electric Motor : 5 HP,
• Perform rated Fiber Sheet,
• Oil tanks
• 5 KL – 2 Nos.
• Bulk Oil Storage tank 25 KL – 1 Nos. (Buyer’s Scope)
• Gas Controlling System
• Gas Pressure Controlling Tan
• Negative Pressure Gas Tank
• Gas Water seal Tank
• Odor Removal tank by Catalysis (Buyer’s Scope) ,
• Flue Gas Collecting System
• Four Collecting Point,
• Flue gas controlling dumper (Manually),
• Scrubber Flue Gas Washing Primary System,
• Dual Scrubber Tank for Secondary Wash with Carbon Filter Ceramic Rings System,
• Flue Gas ID Fan Exhauster– 10 HP,
• Industrial Self Supported Scrubber
• Flue Gas Emission by 30 Meter Height Chimney,
• 12 Meter Platform for Flue Gas Testing,
• 30 Meter Platform with Safety Ladder
• Pyro Gas Flaring System
• 30 Meter Height Auto Gas Ignition System,
• Auto Ignition Transformer, Silicon Cable &Dual Sparking Plug,
• Attached to 30 meter Height Scrubber Chimney,
• Automatic Extra Gas Firing,
• Ventury Connected with Air Blower,
• Ignition Wire Rope 3 MM 100 Feet,
• Controlling Method (Programmed Logic Control - PLC)
• Instruments Measurement of or Temperature and Pressure Control along with its safety Interlocks in case of increase of temperature and pressure of the reactor,
• Instruments Measurement of or Temperature and Pressure Control along with its safety Interlocks in case of increase of temperature and pressure of the reactor,
• Automatic / Manual (Optional) control system,
• Reactor Long Duplex Thermocouple & Pressure Sensor
• Revolving Light Hooter Alarm
• Double Teflon coated Shielded Temp Compensating Cable – 20 meter,
• By Pass Unit with Flexible 3mtr SS Hose Pipe,
• UPS (1 KVA) for improper A.C. Power supply and Earthing
• Data SIM (Min 500 MB data plan) of Mobile operator prevalent in your area to be made available during installation
• Data storage server facility
• D.G Set Required for Power Backup 100 kva
• OPTIONAL MACHINE FOR PLANT
• ETP Plant
• Nitrogen Plant
• Tyre Chips Plant
• Pressure Indicate And Control Systems
• Carbon Packing Machine
• Pyro Oil Separator Tank
• 100 Feet Chimney ( Price Including)
• Auto Ignition 100 Feet Chimney ( Price Including)
• Carbon Cooling Systems
• D G Set As Per Requirement