Anjali Exim - 5 Ton

[email protected]

“Bringing

“WASTE T

Registered Office:

Varachha Road, Surat 395 006 (Guj) India

Contact Numbers:

1

“Bringing You & Technology Together

TYRE RECYCLING P

Registered Office: 520-527 Poddar Arcade, Khand Bazaar,

Varachha Road, Surat 395 006 (Guj) India

Contact Numbers: +91 261 2554150/51/52 Fax: +91 261 2554149

www.anjaliexim.com

You & Technology Together“

PLANT”

527 Poddar Arcade, Khand Bazaar,

1/52 Fax: +91 261 2554149

2

[email protected] www.anjaliexim.com

5 TON PLANT PROJECT REPORT.5 TON PLANT PROJECT REPORT.5 TON PLANT PROJECT REPORT.5 TON PLANT PROJECT REPORT.

Company Profile: Anjali Exim with its unique renewable technology has come up with a concept of setting new standard in renewable energy that includes using of waste

tyres as a raw material and producing green fuel oil, carbon black, steel and gas. With global warming and utilization of rubber, it has now become necessary to recycle the waste and convert it in fuel oil in such a way that it is environment friendly. This is a unique technology and can be change

energy market scenario in a big way.

Anjali Exim has a team of experienced and expert recycling, consulting and marketing Professionals that work hard for obtaining renewable energy from

the waste. Our professionals have worked in different countries. We are also working in the sector of laser systems, solar panel, and textile and

construction business.

World Market Scenario: Billions of wastages are available in all over the world. We can’t burn or land

fills that tyres due to pollution problems. There is no any other use of these waste tyres. So, we at Anjali Exim have found a solution for this wastage tyre. We separate all content from wastage tyres and make it complete renewable process.

3


Features of the plant:

� 100% wastage tyre recycling is achieved (No churn left after the

process)

� No chemical ingredients are used in process (environment friendly)

� During and after the process; no soil, water or air pollution is observed.

� Creates economically valuable products out of wastage tyres (These are

an industrial product that have a good market value and demand)

� The most cost-effective wastage tyre recycling technology in the world.

� Raw material (wastage tyre) is cheap and easy to provide. These are

the by-products of tyre production.

� Each recycled ton of tyres preserves 10 tons of CO2 that is a major

green house gas.

� It is a 100 % pollution free process, thus making eco-friendly

environment.

� The process can be applied to all rubber based materials.

� The system creates an alternate source of energy to replace petroleum

products and natural gas.

� System gives the opportunity to governments and local administrations

to deal with the wastage tyre problem to a great extent.

� The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and size of tyre (car tyre, truck tyre, etc.). During the

process different vacuum values are applied in pre-determined

temperatures and in different phases. Different gases are obtained and

the condensed gas is stored as a fuel-oil in tanks.

4


The Perfect Solution (Pyrolysis Process):

Pyrolysis is the decomposition of organic compounds under oxygen free (anaerobic) atmosphere that produces gas, oil, carbon black and steel. Efficient industrial Pyrolysis is a process to treat the rubber and

industrial plastic wastage as well.

As a result of pyrolysis of wastage tyres one obtains,

� FUEL OIL (40% to 45%)

The main oil product produced by our recycling application is the fuel oil that is wide used for industrial and commercial purposes. The oil has

40% to 45% of the amount of recycled scrap tyres, which will be carried with licensed tanker trucks.

� CARBON BLACK (30% to 35%)

Carbon Black is the main product recycled by Pyrolysis technology. The amount of recycled carbon black is 30% to 35% (depending on the type of tyres) of the total amount of scrap tyres recycled in the system.

Carbon black is used as raw material or main ingredient in many industries and the chemical structure of carbon black strengthens, lengthens the endurance, and improves the coloring features of the materials.

Carbon black produced by Pyrolysis process (CBp) is more economical compared to carbon black produced primarily from petroleum and is

more price-efficient to be used as an ingredient in the industries listed; � Electric cable jacketing

� Conveyor band � Carrier Bands

� Hose and doormat � Black nylon bag

� Rubber additive � Automotive spare parts

� Heat isolation � Black colorant in rubber materials

� Plastic pipes � Industrial rubber products � Fire fighting

[email protected]

� STEEL WIRE (10

Tyres contain steel wires and thetotal tyre wastage

after the Pyrolysis recycling process is completed.

are pressed and sold to steel and scrap dealers.

� GAS (10%

Non-Condensable gases arise duringsome advantages such as…..

• It has higher calorific value as compared to

• It can be replaced• The high energy gas may be utilized as a source of energy for the

Pyrolysis process. • The amount of gas generated in the system is 12

total amount of recycled tyrestyre/day recycling cap

m³/day gasevaluated.

5

STEEL WIRE (10% to 15%)

Tyres contain steel wires and the amount range of 10% total tyre wastage. All of the steel present in the tyre can be

after the Pyrolysis recycling process is completed. Valuable steel wires

are pressed and sold to steel and scrap dealers.

to 12%)

Condensable gases arise during the pyrolysis process. There are some advantages such as…..

her calorific value as compared to natural gas

replaced where natural gas and propane areThe high energy gas may be utilized as a source of energy for the

Pyrolysis process. The amount of gas generated in the system is 12

total amount of recycled tyres and considering the 10 ton scrap re/day recycling capacity, the facility generates 12

m³/day gas, which has an enormous energy potential when

www.anjaliexim.com

10% to 15% of the teel present in the tyre can be detached

Valuable steel wires

the pyrolysis process. There are

natural gas.

where natural gas and propane are stored. The high energy gas may be utilized as a source of energy for the

The amount of gas generated in the system is 12% to 15% of the

and considering the 10 ton scrap acity, the facility generates 1200 -1500

which has an enormous energy potential when

[email protected]

PYROLYSIS CARBON BLACK TEST REPORT:

6


www.anjaliexim.com


7


PYROLYSIS FURNACE OIL TEST REPORT:

8


Technical Detail:

� This is a batch process system. � The wastage tyres are feed into the reactor vessel and heated under

controlled conditions of temperature and pressure.

� The process will bring about molecular restructuring of the rubber under the pyrolysis process as the result; furnace oil in gaseous form is produced along with other gases.

� These vaporized gases are passed through heat exchanges, where in the furnace oil is condensed into liquid form.

� During the process, carbon black and steel are also generated. � The heat exchanger uses coolant water, as a condensing medium and

this water is re-circulated through process.

� These systems can be operated 24/365.

AZ - 100 Tyre Recycling Plant:

[email protected]

Process Flow Chart:

9

Flow Chart:

www.anjaliexim.com

10


Technical Parameter:

Project ( Dimension : 6.0 *2.2m)

Sr. No. Equipment Specification

1 Equipment Model AZ - 100 (Full open door)

2 Material Plastic rubber (tyres) life garbage

3 Structure Horizontal tyre revolves

4 Capacity For One Batch About 5-6 tons wastage tyres

5 Oil Yield 40%-45%

6 Carbon Black 30%-35%

7 Steel Wire 10%-15%

8 Gas 12%-15%

9 Work Pressure Normal

10 Main Engine Rotation Speed 0.4 RPM

11 Fuels Choice Coal, Wood, Gas, Oil

12 Power About 15 HP

13 Cooling Method Water

14 Cooling Water Consumption(T/H) Cyclic

15 Type Of Drive External Annual Gear Drive

16 Heating Method Direct

17 Type Of Installation With Foundation

18 Operating Mode Intermittent Operation

19 Reactor Dimension (MM) (Long*Diameter) 6000*2200

20 Reactor Weight About 8000 Kg.

21 Total Weight About 22 MT

11


WASTE TYRE RECYCLING PLANT COMPONENT (PACKING LIST):

Sr. No. NAME UNIT QTY

1 HA-2-20 type machine（12mm boiler plate） set 1

2 keep-warm shell set 1

3 motor Y132S-6-3KW（wheel 120×38B2） set 1

4 speed reducer JZQ350 set 1

5 sub-air package φ960 pcs 1

6 condenser φ480 pcs 9

7 water block φ800 pcs 1

8 diesel tank φ1200×2700 pcs 1

9 gasoline tank pcs 1

10 self-made pipe fittings elbow φ273（10 flanges) pcs 12

11 Self-made straight pipe φ273×1000 m 15

12 catalytic tower pcs 1

13 φ219 steel pipe（seamless pipe） m 6

14 φ159 steel pipe m 2

15 φ108 steel pipe m 2.3



18 galvanized pipe m 6

19 flue side rounded 240×240-φ273 pcs 1

20 desulphurization and dust removal φ750 pcs 1

21 gas burner devices set 3

22 distribution box（8 side） set 1

23 metal pad φ325-2 ;φ219-3 ;φ89-2 pcs 7

24 φ325 sets of static and dynamic sealing set 1

25 φ219 flange pcs 6




29 φ430 blind panel pcs 1



32 φ325 graphite ring pcs 10

33 soft pipe φ50 m 2

34 one meter stove firebar pcs 60

35 draft fan T6-41-4.5＃2 grade-4KW wheel set 1

36 boiler accessories section

37 Pipe coupling (flat tube clip) pcs 6

38 φ219 elbow pcs 6

39 φ89 elbow pcs 3

12


40 φ59 elbow pcs 6

41 change the first 50 variable 25 pcs 2

42 three connections 50 to 25 pcs 2

43 oil for φ 50 (live) set 3

44 blower 250W pcs 3

45 φ25 valve pcs 6

46 φ50 valve pcs 7

47 valve φ80 set 1

48 double outside wire Φ50 L=150 pcs 8

49 double outside wire φ25 L=150 pcs 5

50 Wire plug (Outer)φ50 pcs 8

51 three connections φ25 pcs 3

52 three connections φ50 pcs 3

53 0-500℃ thermometer pcs 2

54 Y100-0.16pressure gauge pcs 2

55 table bend pcs 2

56 table bottom pcs 3

57 valve φ89 pcs 2

58 aluminosilicate fireproof cotton case 4

59 glass cloth bundle 2

60 asbestos panel§4（or pad） kg 15

61 fire-resistant soil bag 2

62 fireproof stone 3＃ bag 8

63 fireproof cement bag 4

64 φ325 compensator pcs 1

65 300×400 stove door pcs 1

66 stone packing 18×18 m 7.5

67 stone packing 14×14 m 2.2

68 asbestos gloves pair 2

69 screws section

70 ring spanner 30-32 pcs 1

71 stove door nail M12*60 set 8

72 4.8 screw M20*90 set 60

73 4.8 screw M16*100 set 8

74 4.8 screw M16*70 set 80

75 4.8 screw M16*50 set 80

76 M14*50 all wire set 20

77 M10*35 all wire set 30

78 M8*30 set 16

79 M12*50 set 50

80 triangle band B2750 pcs 2

81 sight glasses φ89 set 2

13


Project Planning & Implementation (For the 5 ton/day capacity):

Land Requirement : 15000 sq. Feet Construction Shade : 40Ft * 80 Ft = 3200 Sq. Feet

Water Required : 100 liter per day Power Requirement

Without Autofeeder : 15 hp Man Power Planning : Manager-2

Technical-1 Worker-4

Capital investment:

Other Arrangements to be made by Buyer: Storage tank of oil (Available locally), Civil Work and Local Worker, Labour

Terms & Condition: Delivery Time : 30 days from your order confirmation Installation Period : 15 days

Warranty Period : 1 Year After Sales Service : 1st Year Free Service after then AMC Based. Installation, Training : Inclusive in the price.

and Testing

Particular Investment

Building and land (15000sq.Feet with 3200sq.Feet shade) Depend on the area

Price of the plant (FOR) (Dimension:6.0*2.2m) RS.33,00,000/-

(INCLUDING ALL AT SITE)

This does not include the rate of interest on capital investment.

14


Estimated Operational Cost and Return on Investment: The analysis is based on the conjecture of 5 tons/day capacity unit operating

for 300 days a year; Raw material waste Tyre: 4 ton per day*300 days = 1200 ton/ year.

Total output: • Carbon black (35%) - 420 Ton (Rs 4000 per Ton in India)

• Furnace oil (40%) - 480 Ton (Rs 26000 per Ton in India) • Steel (12%) - 144 Ton (Rs 12000 per Ton in India)

• Gas (13%) - 156 Ton (We are not considering price of it right

now)

Total Earning: (Yearly) (Unit: Tons)

Sr. No Product Output (%) Output (Ton)

Price Per ton. Total Income

1 Carbon Black 35% 420 4,000 16,80,000

2 Furnace oil 40% 480 26,000 1,24,80,000

3 Steel 12% 144 12,000 17,28,000

4 Gas 13% 156 --- 0

Total (A) 1,58,88,000

Total Expense: (Yearly) (Unit: Tons)

Sr. No Particular Quantity Price Total Cost

1 Waste Tyres 1200 7000 84,00,000

2 Salary & Wages 7*12 Month 10000 8,40,000

3 Fuel (For Initial Use) 225 5000 11,25,000

4 Electricity + Water --- -- 3,60,000

5 Misc. Expense

(Bag Packing, Repairing, Renovation)

--- -- 5,00,000

Total (B) 1,12,25,000

Profit (Earning – Expense) (A-B) 46,63,000

15


Contact Us:

Anjali Exim

522-527 Poddar Arcade,

Khand Bazaar, Varachha Road,

Surat 395 006

Gujarat (India)

Phone: +91 261 2554152

Fax: +91 261 2554149

URL: www.anjaliexim.com

Email: [email protected]

Documents

Anjali Exim - 5 Ton