Industry Overview
The increasing number of automotive vehicles driven by growing motorization and industrialization has led to the rapid accumulation of waste tyres worldwide. Billions of discarded tyres pose a significant environmental challenge because they are non-biodegradable and cannot be safely disposed of through open burning or landfilling without causing serious pollution. As a result, effective tyre waste management has become an important priority, particularly in developing countries such as India.
Waste tyre pyrolysis has emerged as a practical recycling technology that converts end-of-life tyres into valuable products under controlled thermal decomposition in the absence of oxygen. The process produces fuel oil, carbon black, pyrolytic gas, and recoverable steel wire, enabling the recovery of useful resources while reducing environmental pollution. Fuel oil produced through pyrolysis can serve as a substitute for conventional fossil fuels in suitable applications, while carbon black, pyrolytic gas, and steel scrap provide additional commercial value. By transforming waste tyres into reusable products, tyre pyrolysis supports sustainable waste management, resource recovery, and the development of a circular economy while reducing dependence on traditional disposal methods.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 20MT/Day |
| Land & Building (8000 sq.mt.) | Rs.3.00 Cr |
| Plant & Machinery | Rs. 1.41 Cr |
| Working Capital for 2 Month | Rs. 2.49 Cr |
| Total Capital Investment | Rs. 7.25 Cr |
| Rate of Return | 52% |
| Break Even Point | 37% |
Content Index
- INTRODUCTION
- PROBLEMS WITH WASTE TYRES
- THE MAIN PROBLEMS WITH TYRE WASTE ARE AS FOLLOWS:
- FACT FINDING RELATED TO TYRES
- PYROLYSIS PLANT PROCESS
- PYROLYSIS END PRODUCTS
- USES AND APPLICATIONS
- USES AND APPLICATIONS OF FUEL OIL
- 1. FOR DOMESTIC USE:
- 2. FOR TRANSPORT:
- 3. IN INDUSTRY:
- 4. AS ROCKET FUEL:
- USES AND APPLICATIONS OF CARBON BLACK
- 1. RUBBER REINFORCEMENT
- 2. COLOURS AND PIGMENTS FOR PLASTICS
- 3. ELECTRIC EQUIPMENT AND CONDUCTIVE COMPONENTS
- 4. OTHERS
- USES AND APPLICATION OF PYROLYTIC GAS
- STEEL WIRE SCRAPS
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS OF FUEL OIL FROM WASTE TYRE
- 1. PROCUREMENT OF SCRAP TYRES
- 2. INSPECTION
- 3. STEEL WIRE PULLING
- 4. TYRE SHREDDING MACHINE
- 5. TRANSPORTATION
- 6. PYROLYSIS PROCESS
- PYROLYSIS END PRODUCTS
- PLANT AND MACHINERY
- MAIN PARTS OF WASTE TYRE PYROLYSIS PLANT AND THEIR FUNCTIONS
- MAIN PARTS OF WASTE TYRE PYROLYSIS PLANT
- THE MAIN COMPONENTS OF THE TYRE PYROLYSIS PLANT
- 1. PYROLYSIS REACTOR
- 2. VACUUM DEVICE
- 3. THE CONDENSER
- 4. CARBON BLACK DISCHARGE DEVICE – WIND CONVEYING SYSTEM
- 5. TAIL GAS CLEANING AND ODOR REMOVAL SYSTEM
- POLLUTION CONTROL SYSTEM IS ADOPTED IN WASTE TYRE PYROLYSIS PLANT
- SMOKE POLLUTION CONTROL SYSTEM OF DOING WASTE TYRE PYROLYSIS PLANT
- ODOR POLLUTION CONTROL SYSTEM OF DOING WASTE TYRE PYROLYSIS PLANT
- MARKET POSITION
- GLOBAL MARKET TREND
- TIRE RECYCLING MARKET SEGMENTATION
- BASED ON RUBBER TYPE
- BASED ON PRODUCT TYPE
- BASED ON END-USER
- BASED ON GEOGRAPHY
- BACKGROUND AND SIGNIFICANCE OF THE TYRE PYROLYSIS PROJECT DEVELOPMENT REPORT-
- RAW MATERIAL MARKET-
- PYROLYSIS PLANT FINISHED PRODUCTS MARKET-
- MAIN REASONS TO SET-UP PYROLYSIS PLANT PROCESS-
- MAJOR DRIVERS OF TIRE RECYCLING MARKET
- PRINCIPLES OF PLANT LAYOUT
- STORAGE LAYOUT:
- EQUIPMENT LAYOUT:
- SAFETY:
- PLANT EXPANSION:
- FLOOR SPACE:
- UTILITIES SERVICING:
- BUILDING:
- MATERIAL-HANDLING EQUIPMENT:
- RAILROADS AND ROADS:
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- SPECIFIC FACTORS
- 6. TRANSPORTATION:
- A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TOTAL LOAD:
- 8. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- PLANT LAYOUT
- PRESENT MANUFACTURES AND SUPPLIERS
- SUPPLIERS OF FURNACE OIL
- SUPPLIERS OF CARBON BLACK
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF TYRES SCRAP
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF WASTE TYRE RECYCLING PLANT
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- 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)
Frequently Asked Questions
A waste tyre pyrolysis plant converts discarded tyres into useful products through thermal decomposition in the absence of oxygen.
The process recovers fuel oil, carbon black, pyrolytic gas, and steel wire from end-of-life tyres. This technology reduces landfill disposal, minimizes environmental pollution, and helps recover valuable materials that can be reused in industrial applications, making it an important solution for sustainable tyre recycling.
Tyre pyrolysis primarily produces fuel oil, carbon black, pyrolytic gas, and steel wire.
Each product has commercial value. Fuel oil can be used as an industrial fuel, carbon black has applications in rubber and plastics, pyrolytic gas is often reused as a process fuel, and recovered steel wire can be recycled through the metal industry.
Tyre recycling helps reduce environmental pollution caused by discarded tyres.
Since waste tyres are non-biodegradable, improper disposal creates long-term environmental and public health concerns. Recycling through pyrolysis enables resource recovery, reduces pressure on landfills, and supports more sustainable waste management practices.
The process includes tyre collection, inspection, steel wire removal, shredding, transportation, and pyrolysis.
After preparation, tyres are processed in a pyrolysis reactor where heat converts them into valuable products. The resulting materials are then separated, collected, and prepared for storage or further industrial use.
Modern tyre pyrolysis plants incorporate pollution control systems to minimize emissions.
Typical systems include smoke control equipment, tail gas cleaning units, and odor removal systems. These technologies help improve environmental performance while supporting safer and more efficient plant operations.
Successful plant setup depends on technical, commercial, and regulatory considerations.
Important factors include reliable raw material supply, market demand for finished products, plant location, utilities, transportation, waste management, safety measures, regulatory compliance, and efficient plant layout to ensure smooth operations and long-term viability.
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