Establishing Sustainable Tyre Pyrolysis Plant: A Report

The growing accumulation of waste tyres has become a significant environmental challenge. Millions of tires need to be disposed of every year.

Tyre pyrolysis offers a sustainable solution to this problem by converting waste tyres into valuable products like fuel oil, carbon black, and steel wire. This tyre pyrolysis plant project report outlines the key aspects of establishing a tyre pyrolysis plant, including feasibility analysis, plant setup, operational processes, economic analysis, and environmental impact assessment.

1. Project Overview

1.1 Project Objectives

• Reduce environmental pollution caused by waste tyres.
• Recover valuable resources from waste tyres.
• Promote sustainable waste management practices.
• Generate economic benefits through the sale of pyrolysis products.

1.2 Project Scope

• Establishment of a tyre pyrolysis plant with a capacity to process 10 tons of waste tyres per day.
• Installation of necessary equipment and infrastructure.
• Implementation of safety and environmental measures.

2. Feasibility Analysis

2.1 Market Analysis

The market for pyrolysis products, such as pyrolysis oil, carbon black, and steel wire, is growing due to the rising demand for alternative fuels and raw materials. Key markets include the energy sector, construction industry, and rubber manufacturing.

2.2 Raw Material Availability

Waste tyres are abundantly available from sources like automotive repair shops, tyre dealers, and landfills. Establishing agreements with these sources ensures a steady supply of raw materials.

2.3 Regulatory Requirements

Compliance with environmental regulations and obtaining necessary permits are crucial. This includes adherence to emissions standards, waste management regulations, and safety protocols.

3. Plant Setup

3.1 Site Selection

Choosing an appropriate site involves considering factors such as proximity to raw material sources, availability of utilities (water, electricity), transportation access, and environmental impact.

3.2 Equipment and Technology

Key equipment includes the pyrolysis reactor, condenser system, oil storage tanks, gas purification system, and carbon black processing unit. Advanced pyrolysis technology ensures efficient conversion and minimal environmental impact.

3.3 Infrastructure

Infrastructure requirements include storage facilities for raw materials and products, safety systems (fire suppression, emergency exits), and waste management systems.

4. Operational Processes

4.1 Tyre Shredding

Waste tyres are shredded into smaller pieces to facilitate efficient pyrolysis. This step involves the use of shredders and conveyors.

4.2 Pyrolysis

Shredded tyres are fed into the pyrolysis reactor, where they are heated in an oxygen-free environment. The thermal decomposition of tyres produces pyrolysis oil, carbon black, and syngas.

4.3 Product Recovery

• Pyrolysis Oil: Collected and stored in tanks. It can be used as an industrial fuel or further refined.
• Carbon Black: Processed and packed for use in rubber manufacturing and other industries.
• Steel Wire: Extracted and sold to steel recyclers.

4.4 Emissions Control

Advanced gas purification systems are used to treat and filter emissions, ensuring compliance with environmental standards.

5. Economic Analysis

5.1 Capital Investment

The initial capital investment includes the cost of land, equipment, infrastructure, and permits. Estimated investment for a 10-ton capacity plant is approximately $1.5 million.

5.2 Operational Costs

Operational costs include raw material procurement, labor, utilities, maintenance, and waste management. Annual operational costs are estimated at $500,000.

5.3 Revenue and Profitability

Revenue is generated from the sale of pyrolysis oil, carbon black, and steel wire. With an average selling price of $450 per ton of pyrolysis oil, $300 per ton of carbon black, and $200 per ton of steel wire, the plant can achieve an annual revenue of $2 million. The projected payback period is approximately 3 years.