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5 GENERATION
WASTE TYRE RECYCLING PLANT

Registered Office: 520-527 Poddar Arcade, Khand Bazaar,

Varachha Road, Surat 395 006 (Guj) India
Contact Numbers: +91 261 2554150/51/52 Fax: +91 261 2554149

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TH

5 GENERATION 10 TON PLANT LAYOUT.

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10 TON PLANT PROJECT REPORT

Company Profile:

Anjali Exim with its unique renewable technology has come up with a concept of setting new
standard in renewable energy that includes using of waste tyres as a raw material and producing
green fuel oil, carbon black, steel and gas. With global warming and utilization of rubber, it has
now become necessary to recycle the waste and convert it in fuel oil in such a way that it is
environment friendly. This is a unique technology and can be change energy market scenario in a
big way.
Anjali Exim has a team of experienced and expert recycling, consulting and marketing
Professionals that work hard for obtaining renewable energy from the waste. Our professionals
have worked in different countries. We are also working in the sector of laser systems, solar
panel, and textile and construction business.

World Market Scenario:

Billions of wastages are available in all over the world. We cant burn or land fills that tyres due
to pollution problems. There is no any other use of these waste tyres. So, we at Anjali Exim have
found a solution for this wastage tyre. We separate all content from wastage tyres and make it
complete renewable process.

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Features of the plant:

100% wastage tyre recycling is achieved (No churn left after the process)
No chemical ingredients are used in process (environment friendly)
During and after the process; no soil, water or air pollution is observed.
Creates economically valuable products out of wastage tyres (These are an industrial
product that have a good market value and demand)
The most cost-effective wastage tyre recycling technology in the world.
Raw material (wastage tyre) is cheap and easy to provide. These are the by-products of
tyre production.
Each recycled ton of tyres preserves 10 tons of CO2 that is a major green house gas.
The process can be applied to all rubber based materials.
The system creates an alternate source of energy to replace petroleum products and
natural gas.
System gives the opportunity to governments and local administrations to deal with the
wastage tyre problem to a great extent.
The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and
size of tyre (car tyre, truck tyre, etc.). During the process different vacuum values are
applied in pre-determined temperatures and in different phases. Different gases are
obtained and the condensed gas is stored as a fuel-oil in tanks.

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The Features of the Fifth Generation Plant

Item.
Catalyst
Room

Picture.

Features.
Two catalyst room, in this way, can
speed up the process of pyrolysis.

Horizontal
Condensor

Two horizontal condenser, the cooling

area of one horizontal condenser can be
equaled with more than three vertical
condensers. And also, the cooling way is
longer than vertical condenser, in this
way, the oil output will be guaranteed.

Vertical
Condensor

Another two length cooling pipes,

cooling area can be equaled with
vertical condenser, in this way,
cooling result will be better than
fourth Generation.

the
one
the
our

Anti back
devices

Two anti back fire devices, it is our

second water seal, and also reuse the
exhaust gas as burning material, two anti
back fire device, more safety, more
energy saving.

The exhaust
Gas

From the picture, you can see the

exhaust gas, it is white, no pollution,
even if you put a white towel on it you
cannot see any black. It can meet the
emission standard of international
required.

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The Perfect Solution (Pyrolysis Process):

Pyrolysis is the decomposition of organic compounds under oxygen free (anaerobic)
atmosphere that produces gas, oil, carbon black and steel. Efficient industrial Pyrolysis is a
process to treat the rubber and industrial plastic wastage as well.
As a result of pyrolysis of wastage tyres one obtains,

FUEL OIL (45% to 50%)

The main oil product produced by our recycling application is the fuel oil that is wide
used for industrial and commercial purposes. The oil has 45% to 50% of the amount of recycled
scrap tyres, which will be carried with licensed tanker trucks.

CARBON BLACK (30% to 35%)

Carbon Black is the main product recycled by Pyrolysis technology. The amount of
recycled carbon black is 30% to 35% (depending on the type of tyres) of the total amount of
scrap tyres recycled in the system. Carbon black is used as raw material or main ingredient in
many industries and the chemical structure of carbon black strengthens, lengthens the
endurance, and improves the coloring features of the materials.
Carbon black produced by Pyrolysis process (CBp) is more economical compared to
carbon black produced primarily from petroleum and is more price-efficient to be used as an
ingredient in the industries listed;
Electric cable jacketing
Conveyor band
Carrier Bands
Hose and doormat
Black nylon bag, Plastic pipes
Rubber additive
Automotive spare parts
Black colorant in rubber materials
Industrial rubber products
Fire fighting

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STEEL WIRE (10% to 15%)

Tyres contain steel wires and the amount range of 10% to 15% of the total tyre wastage.
All of the steel present in the tyre can be detached after the Pyrolysis recycling process is
completed. Valuable steel wires are pressed and sold to steel and scrap dealers.

GAS (5% to 8%)

Non-Condensable gases arise during the pyrolysis process. There are some advantages
such as..

It has higher calorific value as compared to natural gas.

It can be replaced where natural gas and propane are stored.
The high energy gas may be utilized as a source of energy for the Pyrolysis
process.
The amount of gas generated in the system is 5% to 8% of the total amount of
recycled tyres and considering the 10 ton scrap tyre/day recycling capacity, the
facility generates 500 - 800 m/day gas, which has an enormous energy potential
when evaluated.

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5th Generation photo:

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PYROLYSIS CARBON BLACK TEST REPORT:

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PYROLYSIS FURNACE OIL TEST REPORT:

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Technical Detail:
This is a batch process system.
The wastage tyres are fed into the reactor vessel and heated under controlled conditions
of temperature and pressure.
The process will bring about molecular restructuring of the rubber under the pyrolysis
process as the result; furnace oil in gaseous form is produced along with other gases.
These vaporized gases are passed through heat exchanges, where in the furnace oil is
condensed into liquid form.
During the process, carbon black and steel are also generated.
The heat exchanger uses coolant water, as a condensing medium and this water is recirculated through process.
These systems can be operated 24/365.

AZ 150 Tyre Recycling Plant:

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AUTO FEEDAR:

CARBON REMOVAL SYSTEM:

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NEW DESIGN OF CHIMNEY

CHIMNEY:

CARBON BLACK VACUUM COLLECTOR:

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Process Flow Chart:

Scrap Tire

Stocking

Pyrolysis Unit

Oil

Carbon Black

Steel Wire

Gas

Storage

Sleve

Sleve

Burning Unit

Transfer to
Refinery

Carbon Black

Storage

Storage

Chimney

Pressing

Magnet

Transfer to
Scrap Dealer

Grinding System

Stowing

Packing

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Sale to Market

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Technical Parameter:

Project ( Dimension : 6.6 *2.6m)

Sr. No.

Equipment

Specification

Equipment Model

AZ-150

Material

Plastic rubber (tyres) life garbage

Structure

Horizontal tyre revolves

Capacity For One Batch

About 8-10 tons wastage tyres

Oil Yield

45%-50%

Carbon Black

30%-35%

Steel Wire

10%-15%

Gas

5%-8%

Work Pressure

Normal

10

Main Engine Rotation Speed

0.4 RPM

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Fuels Choice

Coal, Wood, Gas, Oil

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Power

About 35 HP

13

Cooling Method

Water

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Cooling Water Consumption(T/H)

Cyclic

15

Type Of Drive

External Annual Gear Drive

16

Heating Method

Direct

17

Type Of Installation

With Foundation

18

Operating Mode

Intermittent Operation

19

Reactor Dimension (MM) (Long*Diameter)

6600*2600

20

Reactor Weight

About 22000 Kg.

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Total Weight

About 32 MT

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5th Equipment List

D = Diameter L = Length H = Height W = Wide
Name

Weight

Size (MM)

Quantity

Reactor

22000 kg

D2600*6600

Catalyst Chamber

H2100*L1800

Oil Water
Separator

D1200*H2100

Oil Tank

D1000*L3200

Horizontal
Condenser

D1050*L400

Vertical
Condenser

300kg

D800*L2600

Anti-back fire
device

50 kg

D400*H1350

Buffer Tank

50 Kg

D550*H1350

Negative Pressure
Device

890 Kg

H2050*W2000

D500*L4000

H1250*L2950

L950*W800

Water Jet Flue

Dust Removing
device

2000kg

Draught Fan
Chimney

200kg

Auto Feedar

400Kg

Picture

1
L4700*W1200*H2150

Releted link pipe

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Difference Between Fourth Generation And Fifth Generation Tyre Pyrolysis Plant
5th Generation Tire Pyrolysis Plant

Name

4th Generation Tire Pyrolysis

Plant

Catalyst
Chamber

We call the 5th catalyst chamber double chamber . This design could add the molecular
sleve , which increase the oil quantity, beside these are two catalyst chamber could reach
double effect of catalytic pressure and remove the slag from the oil gas.
Oil Water
Separator

The Oil Water Separator new design could have the colling cover that cool the gas so that
decrease the temperature of the oil gas, than the oil gas could be more easily collected in
next stage.
Condenser

The condensers are changed as horizental , this could incersase the colling area, so that
more oil gas could be colleted , thes the oil yiekd are higher the oil yield rate could reach
53%.
Oil Tank

The oil capacity is bigger than tha 4th generation and it could be equipped with the
automatic pumping system.

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Anti back
fire Device

Double anti-back fire device could be recyeled the tail gases more sufficently so that the
reactor could burn more gases us fule to save energy and will not pollute the air , so that
more enviromental friendly. Also there are two pipes colling the tall gas to that more safe, as
the fule gas are usally methane , eathane, hydrogen etc, if the temperature is so high then it
easy to blast.
Carbon
black
Removing
Equipment

Our R&D department invent this bucket elevator to lift the carbon black into the come pool
automatically, there is no need manpower ot lift, and also there is a screw conveyor to cool
the hot carbon black then this save time to collect the carbon black.
Electric
Controller

5th generation electric has two function, one is the control the power and another showing
the temprature of the oil out, 4th generation electric could only control the power.

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Project Planning & Implementation (For the 10 ton/day capacity):

Land Requirement
Construction Shade
Water Required
Power Requirement
Without Autofeeder
With Autofeeder
Man Power Planning

:
:
:

1500 sq. meters

40Ft * 80 Ft = 3200 Sq.Feet
100 liter per day

:
:
:

20 hp
35 hp
Manager-2
Technical-1
Worker-4

Capital investment:
Particular

Investment

Building and land (1500sq.meter with 600sq.meter shade)

Depend on the area

CHINESE PLANT
Price of the Plant (Ex Factory China) 5th Generation With
Auto feeder
( Dimension:2.6*6.6MT)
Price of the Plant (Ex Factory China) 5th Generation Without
Auto feeder
( Dimension:2.6*6.6MT)
Custom Duty 26%, Fright, Container Clearing Charges,
Transportation Extra.

65,000 USD

60,000 USD

This does not include the rate of interest on capital investment.

Other Arrangements to be made by Client

Storage tank Of oil (Available locally),Civil Work, Local Worker & labor ,Hydro crane, Plumber,
Electrician, Gus cutter, Welder.

Terms & Condition:

Delivery Time
:Chinese plant 30 days from your order confirmation
Installation Period
:15 days
Warranty Period
:1 Year
After Sales Service
:1st Year Free Service after then AMC Based
Installation, Training & :Inclusive in price.

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Estimated Operational Cost and Return on Investment:

The analysis is based on the conjecture of 10 tons/day capacity unit operating for 300 days a
year;
Raw material waste Tyre: 8 ton per day*300 days = 2400 ton/ year.

Total output:

Carbon black (35%)

Furnace oil (45%)
Steel (12%)
Gas (8%)

- 840 Ton (Rs 1,000 per Ton in India)

- 1080 Ton (Rs 38,000 per Ton in India)
- 288 Ton (Rs 12,000 per Ton in India)
- 192 Ton (We are not considering price of it right now)

Total Earning: (Yearly)

(Unit: Tons)

Sr. No

Product

Output (%)

Output (Ton)

Price Per ton.

Total Income

Carbon Black

35%

840

1,000

8,40,000

Furnace oil

45%

1080

38,000

4,10,40,000

Steel

12%

288

12,000

34,56,000

Gas

8%

192

---

Total (A)

4,53,36,000

Total Expense: (Yearly)

(Unit: Tons)

Sr. No

Particular

Quantity

Price

Waste Tyres

2400

10,000

2,40,00,000

Salary & Wages

9*12 Month

10000

10,80,000

Fuel (For Initial Use)

300

5000

15,00,000

Electricity + Water

---

--

7,20,000

Misc. Expense
(Bag Packing, Repairing, Renovation)

---

--

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Total Cost

9,50,000

Total (B)

2,82,50,000

Profit (Earning Expense) (A-B)

1,70,86,000

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Thank You . . . !

520-527, PODDAR ARCADE,

KHAND BAZAAR, VARACHHA ROAD,
SURAT, 395006
GUJARAT, INDIA.
Phone: +91 261 2554152
Fax: +91 261 2554149
Web: www.anjaliexim.com
Email: info@anjaliexim.com
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