Industry Overview
The disposal of plastic waste and used tyres through landfilling presents growing environmental and economic challenges. The report proposes reprocessing these wastes through pyrolysis to recover valuable products including activated carbon, other solid carbon forms such as carbon black, liquid fuel and gaseous fuel.
The proposed process combines pyrolysis of plastic waste and used tyres, activation of the solid residue, partial combustion of liquid fractions for carbon-black production, and utilization of high-BTU gas for process heat. Activation of the solid residue with CO2 produces CO and activated carbon, while the Boudouard reaction is described for CO2 regeneration and recovery of finely divided carbon that may serve as a substitute for carbon black.
The report discusses established approaches for processing waste plastics, noting that recyclable plastics may be recovered while low-value or non-recyclable materials are commonly sent to landfill or incineration. It presents catalytic conversion and pyrolysis as methods for converting waste plastics into higher-value fuels and chemical products. The resulting distillate fuel is identified for applications including diesel generators, burners, boilers, hot-air and hot-water generators, and diesel pumps, with further fractionation into petrol, kerosene and diesel.
The report also covers activated carbon, including decolorising, gas-absorbent, metal-absorbent and medicinal carbons, together with their manufacturing methods, properties and applications.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 3000 Ltr./Day |
| Land & Building (20,000 sq.ft.) | Rs. 37 Lac |
| Plant & Machinery | Rs. 1.17Cr |
| Working Capital for 1 Month | Rs. 25 Lac |
| Total Capital Investment | Rs. 1.88Cr |
| Rate of Return | 22% |
| Break Even Point | 74% |
Content Index
- INTRODUCTION
- THE DISTILLATE FUEL IS AN EXCELLENT FUEL AND CAN BE USED FOR
- THE DISTILLATE CAN BE FURTHER FRACTIONATED INTO FUELS AS
- DECOLORISING CARBONS
- GAS ABSORBENT CARBONS
- METAL ABSORBENT CHARS
- MEDICINAL CARBONS
- USES AND APPLICATION OF CRUDE OIL/INDUSTRIAL FUEL
- DIESEL ENGINES
- FILTERED CRUDE OIL CAN BE USED IN:
- TYPICAL INDUSTRIAL APPLICATION FOR THE EXPLOITATION OF PYRO FUEL AS THE FUEL
- RAW MATERIALS
- LICENSES FOR MANUFACTURE, STORAGE AND SALE
- STANDARD OF FUEL
- CLASSIFICATION OF PYROLYSIS
- TABLE 1. TYPICAL OPERATING PARAMETERS AND PRODUCTS FOR PYROLYSIS PROCESS
- SLOW PYROLYSIS
- FAST PYROLYSIS
- FLASH PYROLYSIS
- MARKET OVERVIEW OF PYROLYSIS OIL
- SOME OF THE PROMINENT PLAYERS IN THE PLASTIC TO FUEL MARKET INCLUDE:
- PYROLYSIS OIL FROM PLASTIC WASTE
- REACTOR:-
- GAS RECEIVER:
- CATALYTIC TOWER:
- ANTI FLASHBACK DEVICE:
- MODE OF HEATING:
- STORAGE TANK:
- SCRUBBER:
- CHIMNEY:
- FLARING SYSTEM:
- CONTROL PANEL:
- ENVIRONMENT FRIENDLY PROCESS:
- ADVANTAGES OF PYROLYSIS OF PLASTIC/TYRE WASTE POLLUTION
- PROPERTIES OF PETRO ALTERNATE FUEL (PAF)
- PYROLYSIS PROCESS DESCRIPTION
- BIOMASS HEATING
- TABLE: TYPICAL HEATING METHODS USED IN DIFFERENT REACTORS.
- CHAR SEPARATION
- LIQUIDS COLLECTION
- PYROLYSIS PRODUCTS
- TABLE: PYROLYSIS REACTIONS AT DIFFERENT TEMPERATURES.
- PYROLYSIS BIO-OIL
- TABLE: PHYSICAL PROPERTIES AND CHARACTERISTICS OF PYROLYSIS BIO-OIL.
- TABLE: PROPERTIES NO.2 DIESEL FUEL AND PYROLYSIS BIO-OIL FROM DIFFERENT FEED STOCKS.
- TABLE: ELEMENTARY ANALYSIS OF NO 2 DIESEL, COAL AND PYROLYSIS BIO-OIL FROM DIFFERENT FEED STOCKS.
- FIGURE: VARIOUS APPLICATIONS OF PYROLYSIS BIO-OIL.
- DEPOLYMERIZATION TECHNOLOGY
- THERMOCHEMICAL DECOMPOSITION OF THE PLASTIC OR TIRE POLYMER
- BENEFIT OF LOW TEMPERATURE CATALYTIC DEPOLYMERIZATION OF PLASTIC OIL AND TIRES
- TECHNOLOGY, PROCESS AND ADVANTAGE OF PYROLYSIS
- ADVANTAGES OF THE MANUFACTURING PROCESS:
- PROCESS OF CONVERSION WASTE PLASTIC WITH TYRES INTO ACTIVATED CARBON AND INDUSTRIAL FUEL
- METHOD FOR CHAR ACTIVATION
- PROCESS FLOW DIAGRAM
- PROCESS DESCRIPTION IN DETAILS
- FEED STREAM PREPARATION:-
- PYROLYSIS AND CHAR-ACTIVATION UNITS:-
- CARBON-BLACK PRODUCTION:-
- BOUDOUARD CARBON PRODUCTION FROM CO:-
- THE ENERGY BALANCE:-
- METHOD F WASTE TREATMENT TO FUEL AND CHEMICAL USING PYROLYSIS
- MANUFACTURING OF ACTIVATED CARBON
- FUELS AND CHEMICALS FROM POLYMER WASTES
- FIG. 2: SCHEMATIC OF THE FLOW PYROLYSIS LABORATORY EQUIPMENT
- FIG. 3: SCHEMATIC DIAGRAM OF THE THERMAL DECOMPOSITION REACTOR
- FUELS AND CHEMICALS FROM USED TYRES
- FIG. 4: THE DESIGN OF THE PILOT PLANT REACTOR
- FIG. 5: THE VIEW OF THE TECHNOLOGICAL UNIT IN MLIEČANY
- ADVANTAGES OF DSSC/SCA PROCESS:
- ANLYSIS OF FINAL PRODUCTS
- GAS ANALYSIS:
- OIL ANALYSLS:
- CARBON RESIDUE ANALYSLS:
- PROCESS FLOW CHART
- (CONVERSION OF WASTE PLASTIC INTO INDUSTRIAL FUEL)
- PYROLYSIS REACTOR AND TECHNOLOGIS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CATYLYST
- COMPLETE PLANT SUPPLIERS
- OTHER EQUIPMENT SUPPLIERS
- SUPPLIERS OF ROTARY KILN
- SUPPLIERS OF REACTOR
- SUPPLIERS OF TRAY DRIER
- SUPPLIERS OF HYDRAULIC LIFT
- MANUFACTURER OF HEAVY MOBILE CRANES
- SUPPLIERS OF TANKS
- SUPPLIERS OF D.G. SET
- SUPPLIERS OF BOILER
Appendix
- 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)
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