Detailed Project Report on TYRE RECYCLING UNIT (PRODUCTION CAPACITY: 12 TONS/DAY)

The automotive vehicles are increasing rapidly due to increasing motorization and industrialization which definitely leads to generation of tyre waste globally. Billions of waste tyres are available in all over the world. We can’t burn or landfill them due to pollution problems. Disposal of tyre waste is becoming an environmental challenge in many developing countries like India due to its non-biodegradability. Now a day, the developed techniques like pyrolysis process could be used to produce fuel oil from tyre waste to substitute the conventional energy resources/ fossil fuel.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




TYRE RECYCLING UNIT (PRODUCTION CAPACITY:
12 TONS/DAY)
[EIRI/EDPR/4725] J.C.: 2945INR, 2945US$



The automotive vehicles are increasing rapidly due to increasing motorization and
industrialization which definitely leads to generation of tyre waste globally.
Billions of waste tyres are available in all over the world. We can’t burn or landfill
them due to pollution problems. Disposal of tyre waste is becoming an
environmental challenge in many developing countries like India due to its non-
biodegradability. Now a day, the developed techniques like pyrolysis process could
be used to produce fuel oil from tyre waste to substitute the conventional energy
resources/ fossil fuel.

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CONTENTS

INTRODUCTION

PROBLEMS WITH WASTE TYRES

THE MAIN PROBLEMS WITH TYRE WASTE ARE AS FOLLOWS:

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

PROCESS FLOW CHART

MANUFACTURING PROCESS OF FUEL OIL FROM WASTE TYRE

1. PROCUREMENT OF SCRAP TYRES

2. INSPECTION

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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

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

TYRE RECYCLING

TDF - LOW TO MEDIUM VOLUMES

TDF - HIGH VOLUMES

PRIMARY SHREDDERS

SECONDARY SHREDDERS

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TYRE CRUMB

RUBBER POWDER

SEQUENCES STAGE FOR TYRE RECYCLING

STAGE 1: PRIMARY SHREDDING

STAGE 2: SECONDARY SHREDDING

STAGE 3A: PRIMARY GRANULATION

STAGE 3B: FINAL GRANULATION

STANDARD EQUIPMENTCLOSE

STAGE 1

STAGE 2

STAGE 3A

STAGE 3B

TYRE RECYCLING PLANT FOR RUBBER POWDER

RUBBER POWDER PRODUCTION LINE

RUBBER TIRE CRUSHING MACHINE

PROCESSING MATERIALS:

PRODUCTION CAPACITY:

ANCILLARY EQUIPMENT:

FINISHED PRODUCT SPECIFICATIONS:

EQUIPMENT AUTOMATION:

FINISHED PRODUCT USE:

WASTE RUBBER TIRE RECYCLING PROCESS

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TIRE RING CUTTING MACHINE:

TIRE STRIP CUTTING MACHINE:

TIRE CUTTING MACHINE:

TYRE CRUSHER:

MAGNETIC SEPARATOR:

PACKING MACHINE:

MARKET OVERVIEW OF TYRE RECYCLING IN UAE

RUBBER SHEETS PREPARED FROM RECYCLED TYRES

GLOBAL MARKET FOR TYRE RECYCLING

TOP 10 TIRE MANUFACT URING COUNTRIES IN 2021, (INCLUDING IMPORT AND
EXPORT)

TIRE RECYCLING MARKET – SIGNIFICANT GROWTH FACTORS

ENVIRONMENTAL CONCERNS:

GOVERNMENT REGULATIONS:

CIRCULAR ECONOMY PRINCIPLES:

INCREASING DEMAND FOR RECYCLED TIRE PRODUCTS:

GROWING DEMAND FOR SUSTAINABLE CONSTRUCTION:

EMERGING MARKETS AND DEVELOPING COUNTRIES:

TIRE RECYCLING MARKET – MERGERS AND ACQUISITIONS

MICHELIN AND ENVIRO:

LIBERTY TIRE RECYCLING AND BRIDGESTONE AMERICAS:

PYROLYX AND CONTINENTAL CARBON COMPANY:

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SCANDINAVIAN ENVIRO SYSTEMS ACQUIRING TREADCRAFT LIMITED:

LIBERTY TIRE RECYCLING ACQUIRED LAKIN TIRE:

MICHELIN ACQUIRING LEHIGH TECHNOLOGIES:

COMPARATIVE ANALYSIS OF THE RELATED MARKET

TIRE RECYCLING MARKET – SIGNIFICANT THREATS

ILLEGAL DUMPING:

LACK OF INFRASTRUCTURE:

MARKET VOLATILITY:

TECHNOLOGICAL CHALLENGES:

CATEGORY-WISE INSIGHTS

BY PROCESS:

PYROLYSIS:

SHREDDING:

BY PRODUCT:

CRUMBED RUBBER:

TIRE DERIVED FUEL (TDF):

OTHERS:

GLOBAL TIRE RECYCLING MARKET 2023–2032 (BY BILLION)

BY APPLICATION:

MANUFACTURING:

CONSTRUCTION:

RUBBER PRODUCTS:

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OTHERS:

GLOBAL TIRE RECYCLING MARKET 2023–2032 (BY PRODUCT)

TIRE RECYCLING MARKET – REGIONAL ANALYSIS

NORTH AMERICA:

EUROPE:

ASIA-PACIFIC:

LAMEA:

GLOBAL TIRE RECYCLING MARKET 2023–2032 (BY PROCESS)

THE TIRE RECYCLING MARKET IS SEGMENTED AS FOLLOWS:

BY PROCESS

BY PRODUCT

BY APPLICATION

BY REGION

NORTH AMERICA

EUROPE

ASIA PACIFIC

THE MIDDLE EAST & AFRICA

LATIN AMERICA

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

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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:

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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

ADDRESSES OF PLANT AND MACHI NERY SUPPLIERS [CHINA]

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

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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 – 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

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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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COST ESTIMATION

Plant Capacity 12 MT/Day

Land & Building (6000 sq.mt.) Rs. 3.07 Cr

Plant & Machinery Rs. 1.92 Cr

Working Capital for 1 Month Rs. 41.57 Lac

Total Capital Investment Rs. 5.68 Cr

Rate of Return 46%

Break Even Point 49%