Waste Tyre Pyrolysis Plant

JINGCHENG India  has a team of experienced and expert renewable, recycling, consulting  professionals that work hard for obtaining renewable energy from the waste & other  alternative source of energy. 

Technology 

Pyrolysis involves heating organic materials without oxygen to break them down to simpler organic compounds. When organic wastes (e.g., waste tires) are the feedstock, products of the process include char or carbon char, oil, and gas. For example, pyrolysis can convert wood to charcoal and a low-Btu gas.  Gasification of organics occurs at operating conditions between the complete absence of oxygen and stoichiometric (i.e., sufficient oxygen to complete the oxidation reaction).

Gasification involves drying and pyrolyzing a feedstock, and oxidizing the solid char to heat the  reaction and provide carbon monoxide (CO) to the gas. In the early 1980s, the waste industry saw gasification as promising. Gasification processes maximized the effect of carbon-hydrogen ratios. Furthermore, the product gas was suitable for use in existing boilers / Gas Generators for Electricity Generation.  Liquefaction is the thermochemical conversion of an organic solid into a petroleum-like liquid. Liquefaction typically involves the production of a liquid composed of heavy molecular compounds from a pyrolytic gas stream. The liquid has properties similar, but not identical, to those of petroleum-based fuels. Essentially, liquefaction is manipulation of the pyrolysis process in order to produce a liquid with characteristics similar to petroleum-based liquids  (e.g., fuel oils).

Pyrolysis relies on the addition of heat to break chemical bonds, providing a mechanism by which organics decompose and vaporize. Most projects operate within a temperature range of 250° - 500°C, although some report operating at up to 900°C. At temperatures above approximately 250°C, shredded tires release increasing amounts of liquid oil products and gases. Above 400°C, depending on the process employed, the yield of oil and solid tire-derived char may decrease relative to gas production.. 

A typical commercial operation is described below. 

1. Tires delivered to a site are weighed. Tires are introduced to systems whole or else halved,chopped, or shredded;Magnetic separation is often used to remove ferrous metals from size reduced  tires.

2. The feedstock is typically dried and preheated, using tire-derived gas. Oxygen is purgedthrough a combination of the pyrolysis gas preheater and an inert gas system employing nitrogen.

3. Temperature and residence time in the reactor are two key pyrolysis reactor design criteria.Maintaining a positive pressure in the reactor ensures that leaks do not introduce oxygen from the air.

      4.     The liquid stage, tire-derived oil, is condensed and cooled. Light and heavy oil fractions may be                     handled separately. A separator removes any remaining water vapor. The product is filtered.

       5.     Solid tire-derived char is cooled, typically using a water-cooled stage. The product may be sized                  and screened to remove fiber. A magnetic separation stage captures magnetic materials remaining                in the char. washing the char and further size reducing it produces the carbon black  product. 

       6      Tire-derived gas maintains operating pressure in the system and provides heat to the system.                         Vented gases pass through   a pollution control train, which may include a gas flare. 

       7       Gas can further treated for power generation. It is passes through venturi scrubber to remove                       particulate matter from gas and then it is passes through water cooled condenser  which can help                 us    to  bring down the temperature of tire-derived gas and cracking of tar from it. Further it is                        passes through various filters containing wood waste and saw dust waste to remove %moisture                  from gas and finally cleaned through fabric filter.Now our Gas is ultra clean and can directly                            feed to Gas Driven Generating Set. But for continuous operation of generator we proposed low                      pressure vessel for the storage of gas. Through this storage power generation can be done for 24                   hours irrespective  of gas production rate through pyrolysis of waste tires.

8.       Steel shreds are baled for shipment. Separated fibers, when recovery is practical, are baled for shipment. Often, however, fibers are disposed as waste. 

Energy Requirements 

JINGCHENG INDIA reports that the pyrolysis process produces an excess of energy.  JINGCHENG India indicates that the combustion of tire-derived gas provides sufficient heat to drive the reaction. The use of supplemental fuel – Scrap wood - is limited to the startup period. The electrical usage of systems is estimated to 12.8 kWh/ton of feedstock, based on survey responses. The heat required to sustain the pyrolysis reaction appears to be between approximately 630 and 1,025 Btu/lb of feedstock, based on survey responses 

Features of the plant:-

1.     100% wastage tyre recycling is achieved (No churn left after the process)

2.     No chemical ingredients are used in process (environment friendly)

3.     During and after the process; no soil, water or air pollution is observed.

4.     Creates economically valuable products out of wastage tyres (These are an Industrial          product  that have a good market value and demand)

5.      The most cost-effective wastage tyre recycling technology ln the world.

6.      Raw material (wastage tyre) is cheap and easy to provide. These are the by-products of tyre                             production.

7.      Each recycled ton of tyres preserves 10 tons of CO2 that is a major    green house gas.

8.      It is a 100 % pollution free process, thus making eco-friendly  Environment.

9.      The process can be applied to all rubber based materials.

10.    The system creates an alternate source of energy to replace petroleum Products and            natural   gas.

11.   System gives the opportunity to governments and local administrations to deal with the  wastage                 tyre problem to a great extent.

12.   The process of Pyrolysis has duration of 4 to 12 hours, depending onthe quantity and size of  tyre              (car tyre, truck tyre, etc.). During the  process different vacuum values are applied in pre-determined           temperatures and ln different phases. Different gases are obtained and the condensed gas is stored as          a fuel oil in tanks.    

By-Products after Pyrolysis

o Oil  35% to 45%