TENTATIVE ESTIMATE

PRODUCTION

a) Total volume of pyrolyser = 6.8 m3

Vapour space
Solid space
Bulk density of raw materials
Raw material change
Yield of oil @ 50%
Yield after desulpherisation @90%
Recovery / batch
= 20%
= 6.8 x 0.8 = 5.45 m3
= 0.45 T/ m3
= 0.45 x 5.45 = 2.45 T
= 1.225 T = 1360 lit
= 1360 x 0.9 = 1225 lit.

b) Total batch duration:-

• Charging the producer gas gasifier = continuous

• Charging pyrolyser = 15 min.
• Assembly & readying reactor for pyrolysis = 5 min.
• Pyrolysis and oil collection = 60 min.
• Opening reactor & discharge and readying for charging = 10 min.
• Total batch duration = 90 min. (1.5 hrs)
• Theoretical number of batches / day = 24/1.5 = 16

Assume:- 10 batches / day (conservative estimate) = 300 working days

c) Oil production / day = 1225 x 10 = 12250 lit.

Oil production / year = 12250 x 300 = 3675 x 10 m3 lit.
Raw material required / year = 2.45 x 10 x 300 = 7.35 x 10 m3 T
Carbon black / year @ 25% recovery = 7.35 x 0.25 x 10 m3 = 1.8375 x 10 m3 T

d) Total sales / year

@ 0.56$ / lit. of oil
@ 0.66$/kg of carbon black = 0.56$ x 3675 x 10 m3 + 30 x 1.8375 x 10 m3
=2 million +1.22 million
≅ 3.2 million usd
 PRODUCTION COST
Investment:

Plant - 250,000 $
Land - 45,000 $
Facility - Building - 45,000 $
• Shed type
• 200 m2
• PCC floor
• Installed power 50 KW (3φ)
• 10 m3 water

Over head crane ( 5 T ) - 9,000 $

Barrels (1000 nos.) - 12,000 $
Office investment - 3,000$

PC
• Fax
• Furniture
----------------
Total 364,000 $
----------------
 COSTS
Fixed Cost:

1. Interest on investment @ 12% = 18,200 $

2. Depreciation @ 20% for first year
For plant & machinery:
Plant & machinery cost = 250,000
Therefore; Depreciation =250,000 x 0.2 = 50,000$

--------------------------
Total = 68,200 $
--------------------------
-
Running Costs:

a) Materials & Consumables:

1. Raw materials @ 0.04$ / kg for 7350 T = 294,000

2. Wood for gasifier @0.04$ /kg for 4000 T = 160,000
3. Sulphuric acid
(for desulphurization
@ 5% of raw oil) = 0.05 x 3675 T = 183.75 T
And 0.12/kg for H2804 = 183.75 x 120$/ton = 22,050
4. Lime for neutralizing acid sludge
of lime = 12,000
5. Chemicals for laboratory = 4,500
6. Stationery = 4,500
-------------------
Total cost of consumables = 485,000
-------------------
b) Salaries:

-------------
Total = 45,000$
------------------
c) Power:

Pumps - 10 KW
Blower - 5 KW
Illumination - 2 KW
Grinder - 10 KW
Miscellaneous - 5 KW
--------------
Total installed power - 32 KW

Power cost @ 0.17$/KWH = 32 x 24 x 300 x0.17$ = 40,000$

d) Contingencies / Miscellaneous / Spares, etc. = 15,000$

Total Cost = 653,200 ( a+b+c+d)

Sales = 3.1 million

Gross Profit before tax = 2.447 Million US Dollar

PRODUCTION OF FURNACE GRADE FUEL OIL FROM
PYROLYSIS OF WASTE TYRES

1. Process Description:

Refer Fig.1/ The oil is extracted by the pyrolysis (heating the tyre waste to about
350ºC out of contact with air / oxygen). The reaction takes place in the pyrolysis reactor
(PR). The tyres are heated by the combustion gases coming out of the producer gas
generator (GJ). The producer gas, before combustion with limited quantity of air is
scrubbed with water in the scrubber (SCR) to remove the carbon particles and make the
gas clean.

In the pyrolysis gases, the raw material is with the raw material the lid is closed
and the combustion gases from the burning producer gas is hot in so that the raw material
is heated by direct contact. When the temperature of the tyre waste reachers about 200ºC,
the pyrolysis reaction sets in. The pyrolysis reaction continues upto a temperature of 350
ºC beyond which it is not allowed to go by a thermostatic relay which would shut off the
producer gas supply.

The products of pyrolysis reactor consists of the following 3 species:

- Carbon particles
- Light hydrocarbons
- Heavy hydrocarbons

The carbon particles are separated from the mixture through two cyclone
speartors (CS). The remaining product is then fed to a shell and tube water cooled
condenser where the heavy hydrocarbons are condensed to form the fuel oil which is
collected in the receiving vessel (RV). The remaining gas consisting of methane, ethane
and other light organic components are sucked out of the condenser by a water jet eductor
(JE). The mixture of the gas and water coming out of the eductor is then passed through
water separator.

The above gas is then recycled as fuel to produce the combustion gases that will
heat the pyrolysis reactor. Once this is done, there is no necessity of operating the
producer gas generator full capacity. Hence GJ may be shut down or operated at a low
level to supplement the gaseous fuel of pyrolysis gases.

2. Purification of the pyrolysis oil (Desulphurization)

The main impurity in the pyrolysis oil is compounds of sulphur which are formed during
the pyrolysis process through chemical reactions between the sulphur used for
vulcanization and the hydrocarbon and other chemical species. The sulphuric compounds
which are undesirable in the furnace oil are removed as follows:-
Raw oil Concentrated
Sulphuric acid 5 – 6% w/w

ACID …………………… TANK

SETTLING TANK

Purified oil

Acid sludge

Purified oil Sampling for

Lime Sulphur contact, Density,
Viscosity, Carbon residue

Acid ………alization of
sludge
Acid sludge Calciver sulphate
(harmless)
Samples for testing + Disposal
activity non-sulphurous organic
compounds

3. Effluents:

They are from the possible two sources:-

i) producer gas
ii) light hydrocarbons of the pyrolysis gases

The producer gas is generated in the gas generator by the gasification of wood;
the sulphur content of which is practically zero.

The sulphur content of the light hydrocarbon is also negligible since formation of
any SO2 is nil. Since the reactor operates at oxygen free conditions due to controlled
supply of air into the reactor. Hence whatever sulphur present in the original tyre waste
gas only to the pyrolysis oil which is eventually removed by the desulphurization process.