Detailed Project Report on Pyrolysis Plant from Plastic & Rubber

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)