Empresa de Pirolisis de Pneus e Plasticos

Products : Osisco.com

Scrap Tire & Plastic Processing Advanced Pyrolysis Technologies

we offer turn-key Scrap Tires & Plastic Processing System to recover marvelous resources, we do not just offer a standard shredding or milling recycling facility, our patented Pyrolysis technology help living in saver environment and in the same time recover valuable products such as steel wires, carbon black, gas for re-use in the plant and base oil, all that with an absolute positive environment because of no burning cause no smell or release of gases.

Solid wastes threaten human health as well as causing environmental pollution. Developed countries fund research

and development studies that aim to eliminate solid wastes of environment and the most effective method is recycling

since it creates an additional economic value out of waste while cleaning the environment.

Although solid waste reminds the concept of household garbage, in today’s world scrap tires are one of the most

dangerous wastes that requires urgent precautions to be taken against. Worn-out, damaged, old and defaulted tires are

classified as waste or scrap tires and are;

• Flammable (petroleum derivative and hard to extinguish when under fire),

• High in volume (huge dimensions and stocking covers broad areas),

• Poisonous (release poisonous gases while burning),

• Scattered in environment (lack of specific gathering areas; left to garbage dumps, road sides, gas stations,

various kinds of empty territories)

• An environment free of scrap tires is important to the public health. Scrap tires harbor mosquitoes, snakes and

other vermin. West Nile Virus, transmitted by mosquitoes, is a serious health threat.

Plus that open dumps create a public nuisance, divert land from more productive uses and depress the value of surrounding land. They can also pose the following health, safety and environmental threats:

• Fire and explosion• Injury to children playing in or around the dump site• Disease carried by mosquitoes, flies and rodents• Contamination of streams, rivers and lakes• Contamination of soil and groundwater• Contamination of drinking water wells• Damage to plant and wildlife habitats• Decrease in the quality of life to nearby communities and residents


And because of these reasons, scrap tires are dangerous wastes that need to be paid attention to. The amount of scrap

tires in many different countries are expressed in millions of tons.

Scrap tires normally are;

• Burned (to obtain thermal energy which is extremely poisonous)

• Left to garbage dumps,

• Used as barriers,

• Granulized,

• Grazed to be used as shoe-sole material (only exterior part of tire is grazed).

Those are the most common methods to evaluate scrap tires. But none of these are capable of totally eliminating the

scrap tire problem. Granulizing is the process that diminishes the certain rubber-based parts of the tire into small

pieces but since the granulizing process does not compromise the whole tire, considerable amount of tire is left as

scrap, therefore


GRANULIZING IS NOT A RECYCLING OPERATION.

The evaluation methods listed above contribute to the reduction of the amount of waste tires but can never be a long-

term and permanent solution to waste tire problem. This pessimistic picture caused environmental organizations,

universities, research institutions and private entrepreneurs like us to conduct research and development studies over

the recycling methods concerning scrap tires.

We designed and built the first and only “PYROLYSIS WASTE TIRE RECYCLING FACILITY” by using it’s own

equity after 3 years of research and development studies over the technique known as “PYROLYSIS” which is mainly

practiced in universities and laboratories in experimental scales.

The SYSTEM developed to:

• Provides 100% scrap tire recycling (no waste left after the process is completed),

• Does not use any chemical ingredients in the process (environment friendly),

• Does not cause air, soil and water pollution

• Creates economically valuable products out of waste (all of the products are industrial raw materials that have

market values),



OUR SYSTEM

Pyrolysis process is the thermal decomposition of organic materials in an oxygen-free environment and is an

endothermic reaction. It requires an input of heat energy, pressure and pre-determined temperature depending on the

organic material to be pyrolized.

Pyrolysis process has phases and in each phase different decompositions originate therefore different products (steam,

gas, oil, etc.) are obtained. Phases of the process are determined by the process temperature, pressure, duration, and

the variety of organic materials to be processed (scrap tire, plastic bottles, medical waste, etc.).

Our recycling technology is based on the implementation of pyrolysis on waste tires. The optimum phase durations,

temperatures, pressures, vacuum levels, amount of waste tire to be processed and other side factors are determined by

years of experience of research and several laboratory applications.

What makes our process different in waste tire recycling?

• 100% waste tire 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 waste (all of the products are industrial raw materials that have

a market value).

• The most cost-effective waste tire recycling technology in the world.

• Raw material (waste tire) is cheap and easy to provide.

• The system is applicable for the waste tire components (rubber dough, used rubber, granulated rubber, etc.)

which are the by-products of tire production.

• Each recycled ton of tire preserves 10 tons of CO2 that is a major greenhouse gas.

• The recycling facility can be constructed and ready to be operated in 6 months.

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

• The system creates an alternative source of energy to replace petroleum products and natural gas.

• System gives the opportunity to governments and local administrations to deal with the waste tire problem to a

great extent.

• System prevents the spread of diseases caused by waste tires.

• We deliver plants with capacities of 10 ton /day and its multiples.

• We sell the oil as it comes out of the process. Refining does require another plant and licenses. We normally

sell our oil directly to refineries and they distill the oil to obtain light & heavy naphta and some other

petroleum products. As mentioned, we don't apply any other process to oil in our plant.

• We use batch technology instead of continuous system. We supply 4 heat reactors and 12 cartridges for 10

ton / day capacity plant. Details about the process can be found in the document.

• 14 employees are required to operate the plant 24 hours a day.

• Approximately 1000 square-meter closed area (with 7-8 meter ceiling height), 3000 to 4000 square meter land

(depending on the shape of the land) is required for tire stacking, plus100 square-meter building to be used as

office, changing rooms and showers, Lightning conductor, power supply, moving crane (3 ton) and a forklift

(6 ton) are the special utilities that are required for the plant.

• pyrolysis process duration ranges from 4 to 12 hours depending on the amount and type (car tire, truck tire,

etc.) of the recycled tires. During the process different vacuum values are applied in pre-determined

temperatures and obtained gases in different phases are channeled to coolers and the condensed gas is stored

as fuel-oil in tanks.

• The non-condensable gases have a high calorific value and could be used as energy resource in burners for

thermal energy production. Detailed research and development studies for the evaluation of non-condensable

gases are being carried out.

Carbon black and steel wire mixture obtained as the result of the pyrolysis process is sieved and separated by magnets

and carbon black is dispatched to grinding section to be crumbed to 30-40 micron size. Finally packaging takes place.

Steel wires are stored in waste steel gathering area.

The outcome of pyrolysis process depending on the type and amount of waste tire is as follows;

35%-42% fuel oil

35%-42% carbon black

12%-15% steel wire

7%-8% gas


FUEL OIL

The main oil product produced by our recycling application is the fuel oil that is used in industrial and commercial

internal combustion engines with a flashing point of 55 ºC degrees. The oil;

• Occupies 35%-42% of the amount of recycled scrap tires

• Is carried with licensed tanker trucks

• Is used as an energy source in the pyrolysis recycling application in burners

• Produces considerable amount of “naphta” and “number 6 fuel-oil” when decomposed

CARBON BLACK

Carbon Black is the main product recycled by pyrolysis technology. The amount of recycled carbon black is 35%-42%

(depending on the type of tire) of the total amount of scrap tire 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 application (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 pipe

Industrial rubber products

Fire fighting

STEEL WIRE

Tires contain steel wires and the amount ranges from 6%-15% of the total tire weight. All of the steel present in the

tire can be detached after the pyrolysis recycling process is completed. Valuable steel wires are pressed and sold to

steel and scrap dealers.

GAS

Non-Condensable gasses arise during the recycling application which;

• Has a higher calorific value compared to natural gas

• Can replace natural gas and propane when stored

• Can be used as energy resource in gas burners, also used in pyrolysis system

The amount of gas generated in the system is 7%-8% of the total amount of recycled tires and considering the 10 ton

scrap tire/day recycling capacity, the facility generates 900-1000 m³/day gas which has an enormous energy potential

when evaluated.

Batch Processing Scrap Tires Pyrolysis System

The above is a facility layout showing our batch processing system.

The tires first have the steel removed, then are shredded and added to the reactor(s).

The fuel oil is formed and condensed. The remaining carbon black is removed from the reactor and the process is

started over again.

This system can be operated 24/7. Product output is dependent on the number of reactors in the system and how many

hours a day the system operates. An output of approx. 30 tons per day can be achieved.


Batch Processing System - Rubber or Plastic

The above is a facility layout showing our batch processing system that can process either rubber (tires) or plastics.

The tires first have the steel removed, then are shredded and added to the reactor(s).

The fuel oil is formed and condensed. The remaining carbon black is removed from the

reactor and the process is started over again.

For plastics, first they are shredded then added to the reactor(s).

This system can be operated 24/7. Product output is dependent on the number of reactors

in the system and how many hours a day the system operates. An output of approx. 5 tons per day can be achieved

when using two reactors.

Continuous Processing System - Plastics


The above is a facility layout showing our "EEP" system. This is a continuous processing system

that can process plastics. The plastics are shredded then added to the reactor. This system can be operated 24/7. Product output is dependent on the number of reactorsin the system and how many hours a day the system operates. An output of approx. 10 tons per daycan be achieved with the one reactor

Pyrolysis System Flow Diagram

PRODUCTION CAPACITY SCHEME

Scrap Tire

Stocking

GasSteel WireCarbon Black + waste

Packing

Transfer to refinery

Storage

Magnet

Storage

Carbon Black

Sieve

Oil

Pyrolysis Unit

Stowing

Grinding System

Transfer to scrap dealer

Storage

Pressing

Sieve

Chimney

Burning unit

Sale to market

PRODUCTION SYSTEM LAYOUT

SCRAP TIRE~ 10 Tons / day~ 3150 Tons / year

PYROLYSIS

CARBON BLACK

~ 4.1 tons / day~ 1300 tons / year+waste(~250kg/day)

OIL

~ 3.8 tons / day~ 1200 tons / year

STEEL WIRE

~ 1 tons / day~ 315 tons / year

GAS

~ 950 m³ / day~ 315000 m³ / year

1

1

1

1

2

2

2

2

33

4

4

4

45

9

7

7

6

6

6

8


PRODUCTION DIAGRAM Products : Osisco.com

1

7

6

8

9

2

3

4

5

HEAT REACTOR

WATER TANK AND PIPE LINE

COOLERS AND PIPE LINE

FUEL BURNERS

FUEL TANK AND PIPE LINE

OIL TANK

PRIMARY OIL TANK

VACUUM PUMP AND PIPE LINE

CHIMNEY AND BURNER LINES

SCRAP TIRE STORAGE AREA

PYROLYSIS UNIT

COOLING AND VACUUM SYSTEM

OIL STORAGE CHIMNEY AND GAS BURNING UNIT

TUBE DISCHARGE STATION

CARBON BLACK AND STEEL WIRE SEPERATION STATION

STEEL WIRE STORAGE

CARBON BLACK STORAGE

WASTE ELIMINATION

STOWING

PACKING

WASTE STORAGE

GRINDING SYSTEM

MAGNET

COMPONENTS OF THE SYSTEM

• PYROLYSIS REACTORS AND INNER TUBES: System consists of 4 main heat reactors and 12 tubes. 3

tubes are assigned for each reactor to prevent any delays in production due to cooling, filling and discharging.

• FUEL BURNERS: 2 fuel burners are accommodated for each heat reactor.

• COOLING AND VACUUM SYSTEMS: 1 heat exchanger and 1 vacuum unit are attached to each heat

reactor.

• OIL STORAGE TANK: Approximately 40 ton capacity tanks are assembled to the system.

• FUEL TANK FOR BURNERS: 1 ton capacity of a fuel tank is placed to provide fuel to burners.

• COOLING TOWER: A cooling tower is attached to vacuum system.

• GAS CHIMNEY: A chimney with the firing unit is used to burn the discharged gas.

• WATER TANK FOR GAS PRESSURE: A tank filled with water is used to adjust the gas pressure.

• PRODUCT DISCHARGING, SEPARATION AND SIEVING STATION: A closed area is provided to

discharge, separate and sieve the carbon black and steel wires.

• GRINDING AND PACKING SYSTEM: Carbon black is grinded to 30-40 micron size and packed in 25 kg

bags.

• CARBON BLACK STOWING AREA: Packed carbon black bags are stowed on the pallets.

• STEEL WIRE STORAGE AREA: Sieved steel wire is collected in an open area.

• WASTE STORAGE AREA: The separated waste is collected in containers to be transferred to dumping areas.

• SCRAP TIRE STORAGE AREA: Approximately 500 m² area with a cement backcloth is used for scrap tire

storage.

• LIGHTNING CONDUCTOR AND TRANSFORMER: Appropriate lightning conductor and transformer are

installed.

• REPAIR-SHOP: A workplace containing necessary spare parts and machinery is assigned for repair and

renovation.

• GENERATOR ROOM: A power generator room is allocated if needed.

ESTIMATED OPERATIONAL COST AND RETURN ON INVESTMENT ANALYSIS

The analysis is based on the conjecture of 10 tons/day capacity unit operating for 315 days a year;

CARBON BLACK 1300 tons / year

OIL 1200 tons / year

SCRAP TIRE 315 ton / year are produced.

The tubes are approximately filled with 1250-1300 kg of scrap tire. Due to heating and cooling durations only 2

shifts can be managed per day;

(1250 – 1350 kg) scrap tires x 4 tubes x 2 shifts = 10 – 10.8 ton / day scrap tire can be recycled.

Under Estimated domestic prices in Europe:

Carbon Black = ~ $400 / ton

Oil = ~ $500 / ton

Steel Wire = ~ $200 / ton

Yearly income;

Carbon Black 1300 tons x 400 = $520,000

Oil 1200 tons x $500 = $600,000

Steel Wire 315 tons x 200 = $ 63,000

Total = $1,183,000.00

Yearly expenses;

• Cost of raw materials (scrap tires) = unknown in your country

• Employment fees = unknown in your country

• Fuel ( Used only for initial heating, then replaced by gas produced in the system)

= $60,000 / year

• Electricity + water ~ 3,000 x 12 months = $36,000 / year

• Catering & transportation ~ 3,000 x 12 months = $36,000 / year

• Repair & Renovation ~ 2250x 12 months = $27,000 / year

• Carbon Black Packing Bags ~1,500 x 12 months = $18,000/ year

Total expected yearly expenses =$177,000/ year

+ employment fees (Estimated) = $75,000 / year

+ cost of scrap tires (Estimated) =75,000 / year

Total Estimated cost per year =$327,000 / year

Unknown figures are to be determined by the local rules and regulations of the country of the company interested to

invest in the system.

Return on Investment (ROI)

Total Expected income: =$1,183,000 / year

Total Estimated cost: =$327,000/ year

Expected Net profit: =$856,000 / year

Expected return on investment time period less than 18 months, a client is urging to do his own feasibility study and

determine all facts including the major changes for energy/oil prices in the past few months which will certainly effect

the selling prices for his final products and increase profits and decrease the time to return the investment.

Pyrolysis processing systems are custom designed to fit each client's particular application; available waste stream,

desired production capacity, type of end products (gas/ethanol/power/oil/etc.)


Osisco IncAddress:1343 Down place

Philadelphia, Pennsylvania 19116, U.S.A. USA

PresidentKhaled Elsheikh

267-210-6972E-mail:[email protected]

JordanVice president & chief executive of engineering

Adnan Elshareamobile: +(962) 796 327 146Telefax: +(962) 272 413 01mobile+(962)797 073 433

E-mail:[email protected]:[email protected]

Saudi ArabiaFinancial director

Salah Elsheikh+96655 460 8631

E-mail:[email protected]

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Empresa de Pirolisis de Pneus e Plasticos