Industry Overview
The rapid increase in automotive vehicles, motorization, and industrialization has resulted in the generation of billions of waste tyres worldwide. Because tyres are non-biodegradable, their disposal has become a significant environmental challenge, particularly in developing countries such as India. Conventional disposal methods such as burning and landfilling can create serious pollution and environmental problems.
Waste tyre recycling through pyrolysis provides an alternative approach for managing this waste while recovering useful products. The pyrolysis process can convert waste tyres into fuel oil, carbon black, and pyrolytic gas. Fuel oil can potentially substitute certain conventional fossil-fuel resources in suitable applications, while carbon black and pyrolytic gas have applications across different industrial sectors. A waste tyre pyrolysis plant therefore combines waste management with the recovery of valuable products and resources.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 7.34 Ton/Day |
| Land & Building (4000 sq.mt.) | Rs. 4.94 Cr |
| Plant & Machinery | Rs. 1.78 Cr |
| Working Capital for 2 Months | Rs. 49 Lac |
| Total Capital Investment | Rs. 7.40 Cr |
| Rate of Return | 24% |
| Break Even Point | 61% |
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
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS OF FUEL OIL FROM WASTE TYRE
- 1. PROCUREMENT OF SCRAP TYRES
- 2. INSPECTION
- 3. STEELWIRE 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
- 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 TIRE RECYCLING MARKET TREND
- TIRE RECYCLING MARKET SEGMENTATION
- BASED ON RUBBER TYPE
- BASED ON PRODUCT TYPE
- BASED ON END-USER
- BASED ON GEOGRAPHY
- MARKET SHARE BY APPLICATION AND REGION
- MARKET GROWTH
- WASTE TYRE RECYCLING PYROLYSIS PLANT
- RAW MATERIAL MARKET-
- PYROLYSIS PLANT FINISHED PRODUCTS MARKET-
- MAIN REASONS TO SET-UP PYROLYSIS PLANT PROCESS-
- KEY HIGHLIGHTS
- KEY DRIVERS OF TIRE RECYCLING DOWNSTREAM PRODUCTS MARKET
- ASIA PACIFIC A PROMINENT REGION OF TIRE RECYCLING DOWNSTREAM PRODUCTS MARKET
- GLOBAL TIRE RECYCLING DOWNSTREAM PRODUCTS MARKET: KEY DEVELOPMENTS
- TIRE RECYCLING DOWNSTREAM PRODUCTS MARKET: COMPETITION LANDSCAPE
- PLANT LAYOUT
- PRINCIPLES OF PLANT LAYOUT
- 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:
- 6. TRANSPORTATION:
- 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:
- 8. TOTAL LOAD:
- 9. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- PRESENT MANUFACTURES/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 EFFULENT 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 processes scrap tyres through thermal decomposition to recover useful products. In the process, waste tyres are prepared and fed into a pyrolysis system where they are heated under controlled conditions. The process can produce fuel oil, carbon black, pyrolytic gas, and recoverable steel components. It provides an alternative to conventional disposal methods such as landfilling and uncontrolled burning while converting waste material into potentially useful industrial resources.
The main products obtained from waste tyre pyrolysis are fuel oil, carbon black, pyrolytic gas, and recovered steel. Fuel oil may be used in suitable heating and industrial applications, while carbon black can have applications such as rubber reinforcement, pigments, and conductive components. Pyrolytic gas can be utilized within the process or for appropriate energy applications. Steel recovered from tyres can also be separated and directed toward suitable recycling channels.
The waste tyre pyrolysis process generally begins with procurement and inspection of scrap tyres, followed by steel wire pulling and tyre shredding or preparation. The prepared tyre material is then transported to the pyrolysis system, where controlled heating causes thermal decomposition and produces recoverable products. Condensation and separation systems are used to collect liquid products, while gases and solid residues are handled through appropriate process and pollution-control systems.
Fuel oil obtained from waste tyre pyrolysis can be considered for suitable domestic, transportation, and industrial applications, subject to its properties and applicable requirements. The project report specifically identifies domestic use, transport, industry, and rocket fuel among the listed areas of application. Actual use depends on product quality, equipment compatibility, safety requirements, applicable standards, and regulatory conditions governing the use of recovered tyre-derived fuels.
Pollution control systems are important because tyre pyrolysis involves thermal processing and can generate emissions, gases, smoke, and odours that require controlled handling. A properly designed plant incorporates systems for managing process gases and emissions and addresses smoke and odour concerns. Effective pollution-control equipment helps maintain safer plant operations and supports compliance with applicable environmental requirements. The specific equipment and treatment approach should be selected according to process design, emissions characteristics, and local regulatory requirements.
Key location factors include reliable raw-material supply, market access, power and fuel availability, water supply, climate, transportation, waste disposal, labour availability, regulatory laws, taxes, site characteristics, community factors, and flood and fire control. A suitable location should also support efficient movement of scrap tyres, finished products, utilities, and personnel. The report highlights these factors as important considerations in plant location planning and project development.
A waste tyre recycling pyrolysis plant requires process equipment for tyre preparation, pyrolysis, product recovery, material handling, utilities, and pollution control. The report covers tyre shredding machinery, the pyrolysis plant and its principal components, as well as supporting equipment such as DG sets, EOT cranes, power transformers, electrical panels, electric motors, cooling towers, air pollution control equipment, air compressors, weighing machines, material handling equipment, fire-fighting equipment, and water pumps.
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