Fabhind Private Limited

Continuous Pyrolysis Machine Introduction

fabhind

waste tyre pyrolysis plant

• main reactor 

 made with  bq plate 516-70 gr  capsule type (with two site dish end)--2. 6 miter x 6. 6  miter 16 mm plate door size 1500 mm

   front door front side carbon removal system attechmen extra price

• reactor cover 

    cover 3 mm ms sheet with insulated cera wool 1260 temp 25 mm two layer

• reactor electric motor 

    motor -1 nos 7. 5 hp 960 rpm motor for process and 2 nd  7. 5 hp 1440 rpm motor ( standard make )

• reactor gear box

    heavy helical gear box

•   condenser pipe unit

     ms pipe 6 inch -16 nos for condenser with  2 nos carbon holding tank 5 mm thickness.

•  insulation tank

     ms plate 800 mm x 1550 mm x 5 mm with cerawool insulation and  aluminum sheet

• water seal tank

      ms plate 1000 x 1800 mm x 5 mm with 4" jacketed for coolant.

• gas tank

     ms plate  800 mm x 1550 mm x 5 mm

• oil tank

     ms plate  2800 x 1350 mm x 5 mm 7. 4 kl (3. 7 kl -02 nos )

• water coolant pipe

      water coolant pipe with jacketed 5 mm pipe 15 feet ( 8' pipe x 15 feet  & 16" x 10 feet )

• scrubber coolant pipe

     scrubber coolant pipe 10 inch 5 mm with 1' pipe 10" x 15 feet

• wet scrubber round tank for draft control

      scrubber  tank(dust tank)5 mm ms plate with coolant pipe 800x2800 mm

• draft- chimney blower

      dust blower with 5 hp 1440 rpm motor  for chimney                

• steel puling wire-rope hoist

      wire rope hoist  with  4" gear box with 3 hp  motor and 60 feet 10 mm  wire rope

• fire brick & castable cement 

        fire brick & castable cement  550 nos fire brick and castable cement - 5+5 bags for fire chamber

• control penal board       

       reactor control penal board with digital temp indicator & presser  penal board with solenoid valve

• submersible pump

     submersible pump 5 hp "atlas"  brand  for water circulation

• oil gear pump

    oil gear pump "atlas"  brand 3 hp gear pump for oil transfer

• mud pump 

    mud pump "atlas" brand 3 hp for water scrubber systems

• draft chimney 

     draft chimney 

• fire gas fire blower 

      fire gas blower for reactor gas burner 

• gas burner 

    extra gas burner -2 nos for excess gas burning

• cooling tower  

      cooling tower -capacity 70 tr -3 hp motor

• hardware and fitting 

• MAIN REACTOR 

 Made with  BQ Plate 516-70 GR  Capsule Type (with two site dish end)--2.6 Miter x 6.6  Miter 16 MM Plate Door Size 1500 MM

   FRONT DOOR FRONT SIDE CARBON REMOVAL SYSTEM ATTECHMEN extra Price

• REACTOR COVER 

    Cover 3 MM MS Sheet With insulated cera wool 1260 Temp 25 MM Two layer

• REACTOR ELECTRIC MOTOR 

    Motor -1 Nos 7.5 HP 960 RPM Motor for Process and 2 nd  7.5 HP 1440 RPM Motor ( Standard make )

• REACTOR GEAR BOX

    Heavy Helical Gear Box

•   CONDENSER PIPE UNIT

     MS Pipe 6 Inch -16 Nos For condenser with  2 nos carbon holding Tank 5 MM Thickness.

•  INSULATION TANK

     MS Plate 800 MM x 1550 MM x 5 MM With cerawool insulation and  aluminum sheet

• WATER SEAL TANK

      MS Plate 1000 X 1800 MM X 5 MM with 4" Jacketed For coolant.

• GAS TANK

     MS Plate  800 MM x 1550 MM X 5 MM

• OIL TANK

     MS Plate  2800 X 1350 MM X 5 MM 7.4 KL (3.7 KL -02 Nos )

• WATER COOLANT PIPE

      Water Coolant pipe with Jacketed 5 mm pipe 15 feet ( 8' pipe X 15 feet  & 16" X 10 feet )

• SCRUBBER COOLANT PIPE

     Scrubber Coolant Pipe 10 Inch 5 MM with 1' pipe 10" X 15 Feet

• WET SCRUBBER ROUND TANK FOR DRAFT CONTROL

      Scrubber  Tank(Dust Tank)5 MM MS Plate with coolant pipe 800X2800 mm

• DRAFT- CHIMNEY BLOWER

      Dust Blower with 5 HP 1440 RPM Motor  For chimney                

• STEEL PULING WIRE-ROPE HOIST

      Wire Rope Hoist  with  4" Gear box with 3 HP  Motor and 60 Feet 10 MM  wire rope

• FIRE BRICK & CASTABLE CEMENT 

        Fire Brick & Castable cement  550 Nos Fire Brick and castable cement - 5+5 bags For fire chamber

• CONTROL PENAL BOARD       

       Reactor Control Penal board with digital temp indicator & Presser  penal board With solenoid valve

• SUBMERSIBLE PUMP

     Submersible pump 5 HP "Atlas"  Brand  for water Circulation

• OIL GEAR PUMP

    Oil Gear Pump "Atlas"  Brand 3 HP Gear Pump for Oil transfer

• MUD PUMP 

    Mud Pump "Atlas" Brand 3 HP for water scrubber systems

• DRAFT CHIMNEY 

     Draft Chimney 

• FIRE GAS FIRE BLOWER 

      Fire Gas blower for Reactor Gas burner 

• GAS BURNER 

    Extra Gas burner -2 Nos for Excess Gas Burning

• COOLING TOWER  

      Cooling Tower -Capacity 70 TR -3 HP Motor

• HARDWARE AND FITTING 

Waste tyre pyrolysis plants with a 12-ton capacity are available in India, primarily for converting discarded tires into valuable resources such as fuel oil, carbon black, steel wire, and syngas. Here's a breakdown of the key aspects of a 12-ton waste tyre pyrolysis plant:

1. Capacity and output

·         Processing Capacity: 12 tons of waste tyres per batch.·         End Products & Yields:

·         Tyre Pyrolysis Oil: 40-45%        Carbon Black: 30-35%·         Steel Wire: 10-15%·         Syngas (used as fuel for heating): 10-12% 

2. Technology and features

·         Pyrolysis Technology: Utilizes pyrolysis for thermal decomposition under controlled temperature and pressure, according

·         Automation Level: Available in both semi-automatic and automatic configurations.

·         Heating System: Can be heated using various fuels like coal, wood, gas, or oil.

·         Cooling System: Usually features a water circulation cooling system.

·         Safety Features: Equipped with safety mechanisms like auto pressure release, an anti-backfire system, and an emergency shutdown.

3. Applications

·         Fuel Generation: Pyrolysis oil can be used as industrial fuel in boilers, furnaces, and generators.

·         Carbon Black Utilization: Used in industries like rubber, plastics, and pigment manufacturing.

·         Steel Wire Recycling: Can be sold as scrap or utilized in the steel industry.

·         Energy Source: Syngas generated during the process can be used as an energy source within the plant itself. 

·         The final cost is influenced by factors like plant capacity, type of reactor (batch or continuous), location, civil work, pollution control systems, and automation level.

5. Regulatory and licensing requirements

 To establish a waste tyre pyrolysis plant, you will need to obtain licenses and authorizations from various government bodies, including:

·         Udyam (MSME) registration

·         Trade license

·         GST Number

·         Factory License

·         Electricity permission

·         Authorization under Hazardous & Other Waste Rules, 2016 by SPCB/PCC

New Model : 2024

RFC-30 WASTE TYRE PYROLYSIS PLANT

Model :- RFC -30 With All Foundation In Built   

Main Modification Plant

IN-BUILT FIRE UNIT -BENEFIT IN IN BUILT UNIT

 •       Fabricate In I Beam Structure

•       Height 600 MM

•       In built Fire –Pyro Gas / LDO / LPG Gas Fire Systems 

•       Insulation With Height Temperature cera-wool 2 Layer

•       Shell Both Side Ring for Roller long Life

•       LOD Burner – Fitted in Reactor Fire Unit

•       Pyro GAS Burner – Fitted in Reactor Fire Unit

•       LPG GAS Burner – For Pre Heating LOD and Fire Unit

•       Burner Blower – Fitted In Reactor Fire Unit

•       Fire Brick- Fitted In Reactor Fire Unit

•       Not Required Reactor Foundation

•       Not Required Fire Screen

•       With Out Wood Fire Unit

 CARBON COOLING SYSTEMS     

 •       Drum RPM :- Rotating By Gear Motor 5 HP 

•       In Put Carbon  :-  Up to 150 to 200 Temperature

•       Out Put Material  :- Screw With Gear Motor

•       Pipe Line  :-  Heavy Oil Pipe Line 3 Inch With Valve For Heavy Carbon Oil

•       Save Process Time With Safety Position

IN-BUILT PIPE CONDENSER WITH WATER TANK

 •       Capacity 50 KL

•       Bottom Height 7 Feet

•       Pipe 10 Inch, 8 Inch and 6 Inch MS Pipe

A continuous waste tyre pyrolysis plant offers a sustainable and efficient solution for recycling discarded tyres, converting them into valuable resources: pyrolysis oil, carbon black, steel wire, and combustible gas. 

Advantages of continuous pyrolysis plants

Environmental Friendliness: Compared to traditional disposal methods like landfilling or incineration, continuous pyrolysis significantly reduces waste and minimizes harmful emissions. The process is conducted in a sealed environment, eliminating gas leakage and dust release. Modern plants often include advanced exhaust gas treatment systems (desulfurization and denitrification, electrostatic precipitator, and activated carbon dust collectors) to meet stringent emission standards like those in the EU.

High Efficiency & Capacity: These plants are designed for uninterrupted, 24-hour operation with high processing capacities, making them suitable for large-scale waste tyre recycling.

Automation: Continuous pyrolysis plants utilize PLC control systems for automatic feeding, temperature control, and discharge, requiring minimal labor.

yrolysis Oil: Can be used as fuel in industries, for power generation (refined into diesel), or sold directly.

Carbon Black: Can be used as a raw material for rubber products, coatings, and inks, or further processed into higher-quality recovered carbon black (rCB).

Steel Wire: Can be sold as scrap metal for recycling.

Combustible Gas (Syngas): Recycled back into the plant to fuel the pyrolysis reactor, making the process energy self-sufficient. 

Typical working process

Tyre Collection: Waste tyres of various sizes are collected.

Shredding & Steel Wire Removal: Tyres are shredded into small pieces (e.g., 3-5 cm or <15 mm) and steel wires are extracted, crucial for the continuous operation and purity of the rubber material.

Feeding: Shredded tyre chips are transported to a sealed silo and then continuously fed into the pyrolysis reactor using screw conveyors. An inert gas (like nitrogen) system can be used to displace air in the feeding system, enhancing safety and process stability.

Pyrolysis: The reactor is heated (e.g., by burning fuel oil, LPG, natural gas). As the reactor rotates and heats up to around 300°C, the tyres undergo pyrolysis, decomposing into oil gas. Hot flue gases can be recycled to improve thermal efficiency.

Oil & Gas Collection: The hot oil gas enters a manifold system to separate heavy impurities. The condensable components are cooled in a multi-stage condensing system using circulating water, resulting in liquid pyrolysis oil, which is collected in storage tanks. Non-condensable components, mainly syngas, are piped to the combustion system to fuel the burner, achieving energy self-sufficiency.

Waste Flue Gas Treatment: Flue gases from the heating process undergo a series of treatments, including heat exchangers for cooling, a chemical tower for desulfurization and denitrification, and electrostatic precipitators and activated carbon dust collectors for purification, ensuring compliance with environmental standards before discharge.

In India, the Central Pollution Control Board (CPCB) has introduced Standard Operating Procedures (SOPs) for the recycling of waste tyre scrap, emphasizing the use of the Advanced Batch Automated Process (ABAP) and continuous pyrolysis processes. For capacities exceeding 60 tonnes per day (TPD), only continuous pyrolysis plants are permitted. These plants are subject to strict monitoring and adherence to CPCB guidelines for safe and environmentally sound operation. Regulations specify requirements such as minimum land area, treatment of outputs (TPO and charcoal), waste gas treatment systems, wastewater treatment systems, and hazardous waste management authorization. 

RC-15 ECO CONTINUES WASTE TYRE PYROLYSIS PLANT  

Model :-  RC-15- ECO  7500 X 2800 X 16 MM  Bq Plate

MAIN REACTOR

•  Reactor Size  :- 7500 MM X 2800 X 16 MM (Capsule Tyre-)

•  Descent  :-  Both Side Descent

•  Shell Plate  :-  BQ Plate Grade 516:70

•  Front Door Size  :-  Door Size 2000 MM

•  Gas Out Put Pipe  :-  800 MM X 1000 MM With Machining

•  Door Lifting Hoist Stand  :-  C Type Heavy Hoist Stand For Easy Operating

•  Reactor Roller  :-  Make With Special Material Solid Bar With Harding

•  Heating Systems  :-  4000 MM Length With Four Gas Burner And 3 Wood Feeding Window

•  Carbon :-  Front Side 18 Inch Carbon Out Put Systems

•  Gas Out Put Gland Pusher  :-  450 MM And Machining Pipe 450 MM ( 18 Inch )

•  Extra Price  :-  Front Door Carbon Out Put Systems

ACCESSORE

• Single Bin Feeder

• Feeding Belt Conveyor 13 Mtr.

• Carbon Vacuum System

• Carbon Storage Silo 10 Kl

• Carbon Magnet Separator

• Carbon Handling Screw 15 Feet (2 Nos)

• Oil Water Separator Tank- 8 KL

• 100 Feet Chimney With Auto ignition System

• Chimney Blower 10 HP

• 2 Stage Scrubber System

• Control Panel Board

• ETP Plant -5000 Letter Per Day

• Nitrogen Plant 3 NM3 /Hour

• Gas Balloon Systems 150 M3

• Oil Burner Systems

RC-30 ECO CONTINUES WASTE TYRE PYROLYSIS PLANT  

Reactor Two Set With Commons Accessories

Model :-  RC-30. Two Reactor - RC-15- ECO  7500 X 2800 X 16 MM  Bq Plate

COMMON ACCESSORE

•  Single Bin Feeder

•  Feeding Belt Conveyor 13 Mtr.

•  Carbon Vacuum System

•  Carbon Storage Silo 15 Kl

•  Carbon Magnet Separator

•  Carbon Handling Screw 15 Feet (2 Nos)

•  Oil Water Separator Tank- 18 kl

•  100 Feet Chimney With Auto ignition System

•  2 Stage Scrubber System

•  Control Panel Board

•  ETP Plant -5000 Letter Per Day

•  Nitrogen Plant 5 NM3 /Hour

•  Gas Balloon Systems 250 M3

Techicals Datils : -

REACTOR INPUT HOPPER           

•  Capacity :- 100 KG

•  Inlet Flap Valve :-8 Inch 2 Nos

•  Size :-300 X 300 MM

•  Operating :-Pneumatic Type Compressor 5 HP

MATERIAL IN PUT          

•  Main Screw :-Screw With Gear Motor and Tolle

•  Screw Size  :-18  Inch OD Length 5 Feet

•  Warm :- 17.5 Inch 150 MM Pitch

•  Reduction Gear :- 5 Inch NU 10 :1

•  Electric Motor :- 5 HP 1440 RPM

REACTOR ROLLER

•  Roller : - Make In  Solid Bar , Not in  Casting

•  Shaft : Machine In CNC Auto Machine With Grinding

•  Bearing : Heavy Quality No 6316 2 Nos

•  Grease : - High Temp Grease With Feeling Grease Cup

•  Relapses : - Easy Replace

•  Long Life : Every Batch Refile High Temperature Grease 

MAIN MODIFICATION IN RC-15 

•  Reactor Size  :-  7500 X 2800 X 16 MM ( Only Shell Length )

•  Reactor Roller  :-  Made In Solid Special Bar And Harding For Ling Life

•  Main Door  :-   2000 MM For Easy Loading Material

•  Gas Out Put Pipe   :-  800 MM With Machining For Easy Gas Traveling

•  Helical Gear  :-  2000 MM Heavy Steel Material For Easy Running

•  Gear Box :-  Fabhind Gear Box Model 300

•  Reactor Motor  :-  15 HP With VFD Drive

•  Gland Pusher   :-  450 MM Heavy Casting With 450 MM Machining Pipe

•  Carbon Out Put Systems  :-  22 Inch For Fast Carbon Out Put

•  Door Hoist   :-  Heavy C Tyre Clamp

•  Reactor I Beam  :-  All I Beam 300 MM Heavy Duty

•  Reactor Height  :-  Extra Height For Long Life

•  Reactor Cover Gap   :-  Extra Cover Gap For Easy Draft Out Put

•  Coolant Condenser  :-  6 Inch 24 Nos Pipe

•  Carbon Holding Tank  : -  3 Nos For Extra Carbon Holding

•  Back Up Condenser  :-   Extra 2 Nos Back Up Condenser For Recover Extra Oil

•  Reactor Cooling Systems  :-  7.5 HP Vacuum Blower With Four Out Put Header

•  Reactor To Insulation Tank  :-  18 Inch Gland Push / Measuring Pipe / Machining Pipe

•  Scrubber Systems  :-  2 Nos Scrubber Tank With 12 Inch Pipe

•  Reactor Cover Cera Wool  :-  Two Heavy Layer With SS Supporting Rod

•  Pyro Gas Burner  :-  Easy To Clean Systems

Fab-24 Waste Tyre Pyrolysis Continuous Plant
Varticals Screw Tyre 3 Reactor 

waste tyre pyrolysis plant

A waste tire pyrolysis plant is 

a recycling system that uses thermochemical processes to convert end-of-life tires into valuable resources, including pyrolysis oil, carbon black, and steel wire. This method helps address the environmental issues caused by tire waste, such as landfill contamination, while creating profitable products. 

The pyrolysis process

Pyrolysis is the chemical decomposition of organic materials by heating them to high temperatures in the absence of oxygen. In a waste tire pyrolysis plant, the process works as follows: 

1.     Pre-treatment: Waste tires are collected, sorted, and shredded into smaller pieces to prepare them for the pyrolysis reactor.

2.     Pyrolysis: Shredded tires are fed into an oxygen-free reactor and heated to 400°C–500°C. The rubber molecules break down into smaller hydrocarbon molecules, which turn into vapor.

3.     Condensation: The hot oil gas is sent through a condensing system, where it is cooled and converted into a liquid fuel, known as pyrolysis oil.

4.     Residue discharge: The solid residue left in the reactor, consisting of carbon black and steel wire, is discharged using a screw conveyor.

5.     Exhaust gas treatment: Non-condensable flammable gases are recycled to heat the reactor, while other exhaust gases are treated through a scrubbing system to meet environmental standards. 

End products and their applications

A waste tire pyrolysis plant can achieve up to 100% recycling, turning waste into useful resources with no landfill waste. The primary end products include: 

·        Pyrolysis Oil

This high-calorific fuel can be sold as an alternative to fossil fuels for industrial heating in boilers, furnaces, and cement kilns. It can also be further refined into non-standard diesel for use in heavy machinery or generators.

·        Carbon Black

The recovered carbon black (rCB) can be processed into different grades for use as a filler in new rubber products, such as tires and other rubber goods, or as a pigment for coatings and printing inks.

·        Steel Wire

The steel wire remaining after the process can be sold as scrap steel to be re-smelted and used in steel manufacturing.

·        Syngas

The non-condensable gas produced during pyrolysis has high energy content and is typically recycled to provide fuel for the pyrolysis process itself, making the plant energy self-sufficient. 

Types of pyrolysis plants

There are two main types of waste tire pyrolysis plants, differing primarily in their operational scale and automation: 

·        Batch-type: Suited for small to medium-scale operations, a batch plant processes a fixed amount of tires and must be cooled down after each cycle to discharge the carbon black and steel and load the next batch. It is generally more labor-intensive.

fabhind

waste tyre pyrolysis plant

rc-10/16 mm - capacity 10 tons – per batch

• main reactor 

 made with  bq plate 516-70 gr  capsule type (with two site dish end)--2. 6 miter x 6. 6  miter 16 mm plate door size 1500 mm

   front door front side carbon removal system attechmen extra price

• reactor cover 

    cover 3 mm ms sheet with insulated cera wool 1260 temp 25 mm two layer

• reactor electric motor 

    motor -1 nos 7. 5 hp 960 rpm motor for process and 2 nd  7. 5 hp 1440 rpm motor ( standard make )

• reactor gear box

    heavy helical gear box

•   condenser pipe unit

     ms pipe 6 inch -16 nos for condenser with  2 nos carbon holding tank 5 mm thickness.

•  insulation tank

     ms plate 800 mm x 1550 mm x 5 mm with cerawool insulation and  aluminum sheet

• water seal tank

      ms plate 1000 x 1800 mm x 5 mm with 4" jacketed for coolant.

• gas tank

     ms plate  800 mm x 1550 mm x 5 mm

• oil tank

     ms plate  2800 x 1350 mm x 5 mm 7. 4 kl (3. 7 kl -02 nos )

• water coolant pipe

      water coolant pipe with jacketed 5 mm pipe 15 feet ( 8' pipe x 15 feet  & 16" x 10 feet )

• scrubber coolant pipe

     scrubber coolant pipe 10 inch 5 mm with 1' pipe 10" x 15 feet

• wet scrubber round tank for draft control

      scrubber  tank(dust tank)5 mm ms plate with coolant pipe 800x2800 mm

• draft- chimney blower

      dust blower with 5 hp 1440 rpm motor  for chimney                

• steel puling wire-rope hoist

      wire rope hoist  with  4" gear box with 3 hp  motor and 60 feet 10 mm  wire rope

• fire brick & castable cement 

        fire brick & castable cement  550 nos fire brick and castable cement - 5+5 bags for fire chamber

• control penal board       

       reactor control penal board with digital temp indicator & presser  penal board with solenoid valve

• submersible pump

     submersible pump 5 hp "atlas"  brand  for water circulation

• oil gear pump

    oil gear pump "atlas"  brand 3 hp gear pump for oil transfer

• mud pump 

    mud pump "atlas" brand 3 hp for water scrubber systems

• draft chimney 

     draft chimney 

• fire gas fire blower 

      fire gas blower for reactor gas burner 

• gas burner 

    extra gas burner -2 nos for excess gas burning

• cooling tower  

      cooling tower -capacity 70 tr -3 hp motor

• hardware and fitting