Published on February 18, 2014
Divum Consulting The Challenge of Waste Tyres Presented by Michael Clay
Introduction Tyres have been manufactured and designed to exacting standards to achieve; – Long-lived safety – High performance – Durability These same design criteria also makes them very difficult to re-cycle.
Background Tyres are very difficult to re-cycle due to their molecular bonding. Tyre storage poses unique risks, including fire and, in warmer climates, the harbouring of mosquitoes in stored water. A fire in a tyre storage facility is very difficult to extinguish and some have been known to burn for many months They also present massive public service problems, including air polution and contamination to water supplies.
Volumes of Tyres It is estimated that there are in excess of 1Billion tyres stockpiled around the World Each year, a further 1.4Billion tyres are added to the Global stockpile.
Composition of a Tyre
Schematic 2 Whole Tyre Feeding Heat Recovery System Rubber Flakes Magnetic Separator Shredder/ Crusher Scrap Silo Recovered Not Gas Used As Fuel Burners Steel Wire Collections Pyrolysis Reactor Packing Dryer Condenser Filters Recovered Oil Storage Carbon Black Silo Packing Storage
Commercial Advantages Self-sustaining systems with low operating cost. Fully automated with very low manpower requirements. Ability to adjust output quality of recovered oil. Closed, continuous-feed system that increases efficiency and overall effectiveness of process. No pollutant emissions. Flexibility in pricing policies for end-products because of independence from raw material price fluctuations. End-products such as carbon black, oil and steel are commodities. International recognition for deploying an environmental technology that helps to solve one of the biggest waste accumulation problems. Modular system for later-stage expansions.
Overall Benefits Ecological Safe sound in operation Commercially Applicable viable all over the World
Overall Benefits Operates in Accordance with EU Directive 91/156/EEC Production of high value energents from waste material (tyres) Reduction at source, re-use, re-cycle, energy recovery, disposal Secure supply of input raw material (waste tyres volume is increasing) Closed ecological process, no harmful influence on environment, Input material is 100% recycled and re-used Unit can be modified to include the pyrolysis of plastics, such as dirty plastics and car fluff.
Design Proposition This facility has been designed with 5 basic principles in mind; – It must meet and exceed current emissions criteria in both Europe and in the USA – It must be a sound commercial proposition – It must be semi-automatic in operation – It must be safe to operate – It must have an operating life in excess of 10 years
The Proposition The Pyrolysis unit has been 4 years in the design and development. It meets and exceeds both the European and US regulations on emissions. It has been designed to last well in excess of 10 years. It can also handle certain plastics, coal tar and waste oils
Accommodation Needs The Pyrolysis unit is modular in design and is transportable. A Single unit, (including the refinery) may be housed in a structure only 7m high, 5m wide and 60m long (a floor area of only 300 sq metres)
Commercials - 1 A single Pyrolysis unit can process 2224 metric tonnes (mt) of scrap, shredded tyres/day (>8,000 mt/year) It can produce the following; – Carbon black 3,600mt – Steel 560mt – Pyrolysis Oil 3,000mt – Flammable gas 800mt 43% 7% 40% 10%
Commercials - 2 By value, the output is as follows; It can produce the following:– – – – Carbon Black @US$750/mt 3,600mt US$2.7m Steel @US$320/mt 560mt US$179,200 Flammable gas is used within facility for the burners *Pyrolysis Oil @US$900/mt 3,000mt US$2.7m Total is US$5.579m *Note; this is for carbon black at N660 quality; the add-on refinery can achieve activated charcoal with a resale value in excess of US$1,400/mt making the by products EVEN MORE VALUABLE
Commercials - 3 A single Pyrolysis unit costs around US$6.5m, and is subject to a site survey; includes the following; – Full turn-key installation including training. – 8,000 operating hours warranty – Delivery and installation Excluded is the following; – – – – – – Supply of feedstocks Land and shed/s Groundworks Manpower to operate Connection to grid and operating power Taxes and import duties
Commercials - 4 For a single Pyrolysis unit costing around US$6.5m, payment terms are as follows; – 50% deposit with order – 40% some 8 weeks before shipping – 10% on sign-off of commissioning The option of manufacturing incountry is available.
Summary Pyrolysis, a much misunderstood technology, has a valuable part to play in recycling certain specific waste products – and in a commercially viable manner. This unit is optimised for tyres and certain waste oils. The optimum method of operating is in groups (pods) of 4 pyrolysis machines. Each Pod is capable of processing some 32,000 mt of tyres annually (3.2m tyres), a pod can generate some US$19m gross (less labour, land, power requirements and taxation) per annum from a capital outlay of US$26m The ROI should be achieved within 2.5 years
Conclusion Operating as Pods (groups of 4) will provide certain economies of scale and improve the ROI. Full training and technical support will be provided. Each Pyrolysis unit is able to provide data electronically 24/7 to our Control Centre to monitor performance and assist in achieving optimum throughput.
Thank you for your time Contact :- Michael Clay Divum Consulting email@example.com Tel: +44 (0)207 969 2789 +44 (0)7847 61 40 50
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