PYROLYSIS PLANT FROM PLASTIC & RUBBER
[EIRI/EDPR/1447] J.C.226
INTRODUCTION
The disposal of plastic waste and used tyre by land filling is becoming an increasingly serious problem from a environmental and economic stand point, a better solution is to reprocess tire into valuable products such as activated carbon other solid carbon form (e.g. carbon black) and liquid and gaseous fuel.
A process design is proposed which involves pyrolysis of plastic waste and used tires, activation of the solid residue, partial combustion of liquid to produce carbon black and the use of high BTU gas for process heat. The activation of the solid residue is done using CO2 which produces CO and activated carbon.
The CO2 is regenerated and the lost carbon is recovered using the boudouard reaction to produce CO2 and finely divided carbons. The latter material may be used as a substitute for carbon black.
For many years, various methods are tried and tested for processing of waste plastic. The plastic materials are recycled and low value products are prepared. Plastic materials which cannot be recycled are usually dumped into undesirable landfill.
Worldwide almost 20% of the waste stream is plastic, most of which still ends up in landfill or at worst it is incinerated. This is a terrible waste of a valuable resource containing a high level of latent energy.
In recent year this practice has become less and less desirable due to opposition from Government and environmentally conscious community groups. The value of plastics going to landfill is showing a marginal reduction despite extensive community awareness and education programs.
Research Centre for Fuel Generation (RCFG) has conducted successful 300 successful pilot trials and commercial trials for conversion of waste plastic materials into high grade industrial fuel. The system uses liquefaction, pyrolysis and the catalytic breakdown of plastic materials and conversion into industrial fuel and gases. The system can handle the majority of plastic materials that are currently being sent to landfill or which have a low recycle value.
COST ESTIMATION
Plant Capacity 1.00 Ton./Day
Land & Building (600 Sq.Mtr) Rs. 81.75 Lacs...
Plant & Machinery Rs. 40.00 Lacs.
W.C. for 1 Month Rs. 5.46 Lacs
Total Capital Investment Rs. 1.31Cr..
Rate of Return 15%
Break Even Point 69%
CONTENTS
INTRODUCTION
USES AND APPLICATION OF CRUDE OIL/INDUSTRIAL FUEL
USES AND APPLICATION OF ACTIVATED CARBON
END-USER INDUSTRIES OF ACTIVATED CARBON
PROPERTIES AND GRADE OF ACTIVATED CARBON
DIFFERENT TYPES OF ACTIVATED CARBON
DECOLORIZING AND PURIFYING LIQUID
CATALYST & CATALIST SUPPORT (GAS ABSORBENT CARBON
RAW MATERIALS
LICENSES FOR MANUFACTURE, STORAGE AND SALE
STANDARD OF FUEL
B.I.S. SPECIFICATION
SPECIFICATION AND TESTING OF ACTIVATED CARBON
MARKET SURVEY
MARKET TRENDS OF ACTIVATED CARBON
PRESENT MANUFACTURERS OF ACTIVATED CARBON
DEPOLYMERIZATION TECHNOLOGY
BENEFIT OF LOW TEMPERATURE CATALYTIC DEPOLYMERIZATION OF PLASTIC OIL AND TIRES
INPUT AND OUTPUT RATIO OF DEPOLYMERIZATION OF PLASTIC/TYRE
TECHNOLOGY, PROCESS AND ADVANTAGE
PROCESS OF CONVERSION WASTE PLASTIC WITH TYRES INTO ACTIVATED CARBON AND INDUSTRIAL FUEL
PROCESS FLOW DIAGRAM
PROCESS DESCRIPTION IN DETAILS
METHOD F WASTE TREATMENT TO FUEL AND CHEMICAL USING PYROLYSIS
ANLYSIS OF FINAL PRODUCTS
PROCESS FLOW CHART
PYROLYSIS REACTOR AND TECHNOLOGIS
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
COMPLETE PLANT SUPPLIERS
SUPPLIERS OF PLANT & MACHINERY
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
