GoodRich offers vertical pyrolysis plant from Russia. It is designated for processing & utilization of used tyres, industrial rubber wastes, medical wastes, oil processing & refinery wastes, oil sludge, soft roofing materials, e-waste, rubber fabric, textile wastes including oiled rags, paper, cardboards, wood shavings, coconut shells, latex rubber wastes etc.

The main processed products are liquid pyrolysis oil, carbonaceous residue (pyro-carbon), metal cord (in case of tyre processing) & pyrolysis gas.  The gas is used in the process.

Vertical pyrolysis is a new technology. The manufacturer started operations in Russia 3 years back & since then sold more than 50 units. The plant is certified by the Russian State ecological department as suitable to process as many as 904 types of wastes in Russia. The plant is certified to operate in Europe also.

Process description – 

 Crushed raw material is loaded into a heat-resistant stainless steel vessel (retort) of 2.5 m³ capacity. The retort is placed into the Furnace. Preliminary retort heating (approximately 30-40 minutes) is made using liquid fuels (around 10 litres of diesel / furnace oil / pyrolysis oil). When the temperature inside the retort reaches to 300°C, thermal decomposition process starts.The temperature & pressure values are shown in the control panel & there is a pressure valve for safety precaution.

The generated gas is supplied to the heat exchanger for condensing into pyrolysis oil. A part of the un-condensed gas, after multi-stage purification, is supplied to the burner. Thus, from the starting of the pyrolysis process until its termination, the burner fully operates on pyrolysis gas. The pyrolysis process lasts for approximately 10-11 hours.

When the pyrolysis process is completed, the first retort is taken out from the furnace & placed for cooling and the second retort (already loaded with the raw material) is placed into the furnace.

Approximately 5-6 hours later, the cooled retort (containing pyro-carbon & metal cord) is unloaded by over-turning. Further, the retort is placed into a pit for loading the next raw material lot. Metal cord is separated from the pyro-carbon manually or by a magnetic separator(in case of tyre processing).

 Advantages of Vertical Pyrolysis Unit –

• Universality – it can process any carbon-containing waste;
• High-quality components and materials;
• Removable retorts made from fire-resistant stainless steel;
• The furnace is covered by ceramic fiber, which ensues fast heating without heat losses;
• Low electricity consumption;
• High-quality liquid fuel and gas burners from the world’s leading producers;
• Mobility;
• Easy operation and maintenance;
• Full compliance with modern requirements and standards, it is environmentally safe;
• Operation under any weather conditions-24 hours a day& 330 days in a year;
• Complete certification dossier; &
• Optimal value-for-money.

Technical features & Equipment list –

 Complete set and technical features of Pyrolysis plant –

Pyrolysis module (pyrolysis furnace)  –   Efficiency, 2-4 tons/24 hours

Retort with a lid (2 units)   –     Power consumption, 3 KW

Refrigerator (heat exchanger)    –   Dimensions,    4000х3000х7000 mm

Collector-separator   –     Voltage, 220 or 380 V

Centrifugal separator   – Current frequency, 50 Hz

Liquid fuel burner

Gas burner

Pump for pyrolysis oil

Water pump

Compressor for the burner

Pyrolysis gas purification module

Service platform

Control panel

Scheme of the Pyrolysis Plant –

Recovery of final products from various raw materials –

Approximate recovery figures –

1)   Recycling of used tyres –

Pyrolysis oil –   37-40%

Carbon –   38-40%

Steel cord – 3-8%

2)   Plastics processing –

Polyethylene, polypropylene, polystyrene-

Pyrolysis oil – 65-75%

Pyro carbon – 15-25%

Polyurethanes –

Pyrolysis oil – 50-55%

Pyro carbon   35-40%

3)   Oil sludge –

Pyrolysis oil – 44%

Carbon – 18%

Gases – 25%

4)   Waste oil & oil slime –

Pyrolysis oil – 80%

Pyro-carbon – 10%

Gases – 10%

Notes:

1)   The heat value of pyrolysis oil is 9,000-10,000 kcal/kg.

2)  If there is water in the raw material, it cannot be separated from the oil. Usually, water has higher density & can settle down. The process of pyrolysis takes longer time when the raw material has more water.

  Site requirement & utilities –

A concreted plot of 5X5 metres is needed for placing the pyrolysis unit. Additional premises to store the raw materials & finished products, as well as to place the retorts for cooling, should be provided. The unit can be placed outdoors as well as indoors with additional ventilation. The chimney height should be at least 7 metres.

The unit operation needs circulating water (30-40 litres per minute or 10-15 m³ in storage) & electricity (3 KW). A hoisting device (monorail, crane or winch) with a loading capacity of 2 tons & lifting height of 7 metres is needed for loading & unloading the retort. Load-lifting mechanism costs 1,000,000 Roubles extra.

The equipment operates for 24 hours a day. Operating of 1-3 modules requires 2 trained operators. Maintenance is needed once in a week, for 10-12 hours.

Equipment price & Warrantee –

 –  Price of the unit is 5,000,000 Roubles, ex-factory, Moscow. Transportation to St. Petersburg Port in a 40 ft. container costs 30,000 Roubles extra. Shipping weight is about 6 tons.

–  Production capacity is 2-4 tons / 24 hours or 50-100 tons/month.

–  The equipment production time is 60 days.

–  Equipment life is 10 years. Warrantee period is 1 year.

A Russian engineer will come to India for 4-5 days to assemble & to start the unit. The customer has to pay for the flight + accommodation and also a daily bata of 5,000 Roubles.

Additional Equipments –

 Bead cutting device is designated for separating tire beads from treads for denser retort loading. The price is 300,000 Roubles.

 Dumping device is for convenient retort overturning for carbonaceous residue unloading. The price is 200,000 Roubles.

Retort cooling station is designated for more intensive retort cooling. The price is 250,000 Roubles.

Magnetic separator is designated for extracting metal cord residue (more careful purification), which significantly increases its selling price. (they suggest separator producers).

Twin Pyrolysis Plant –

 The Twin Pyrolysis Plant can be purchased for 9,500,000 Roubles, having a capacity to process 4-8 tons per day.

The advantages of Twin Pyrolysis Plant are –

1)  There is no need to use oil burners every time,to start the unit. The gas generated from the first unit can be used to heat the second unit. The process phase shift between 2 units can be chosen in such a way that the second unit goes through the stage of maximum gasification, when the first unit has the biggest necessity of fuel. It is also not necessary to install a gas holder for temporary storage of pyrolysis gas.

2)  Requirement of labourers & supervisors will be the same either for a single unit or for a Twin unit.